Chevrolet - Astro Van Awd - Workshop Manual - 2003 - 2003

Factory Workshop Manual Make Chevrolet Model Astro Van Awd Engine and year V6-4.3L VIN X (2003) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 23 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 24 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 25 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 26 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 27 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 28 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 29 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 30 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 31 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 32 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 33 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 34 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 35 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 36 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 37 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 38 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 39 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 40 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 41 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 42 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 43 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 44 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 45 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 46 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 47 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 48 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 49 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 50 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 51 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 52 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 53 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 55 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 56 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 57 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 58 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 79 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 82 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 Retained Accessory Power (RAP) Diagram 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 94 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its limit. The BCM turns OFF the RAP function and de-energizes the RAP relay when one of the following conditions are met: The BCM senses the opening of any door or the liftgate. - The BCM detects a decrease in battery capacity below a prescribed limit. - The BCM receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The transition from OFF to RUN/ON on the ignition switch. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module energizes the RAP relay. This provides power for the following: DIC - power window control switches - power door lock control switches - steering wheel control switches - radio - outside rearview mirror switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with a Diagnostic System Check - Accessory Delay Module. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1 - 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 97 Steps 3 - 5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit.The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 98 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. VISUAL/PHYSICAL INSPECTION - Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1 - 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 99 Steps 4 - 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 100 Steps 1 - 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 109 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 114 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 119 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 120 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 126 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 143 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 148 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 149 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 171 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 172 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 173 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 179 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 180 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 181 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations Door Lock Relay: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 186 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 187 Door Lock Relay Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations Body Wiring - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations > Page 191 Liftglass Lock/Unlock Relay Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications ABS / Traction Control Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations Electronic Brake Control Module: Component Locations Undercarriage Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 198 Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 199 Electronic Brake Control Module: Connector Locations Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 200 Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 201 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C1 Electronic Brake Control Module (EBCM) C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 202 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the electrical connectors from the EBCM. 3. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (5). 4. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 5. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws (1). Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 203 1. Install EBCM (2) on to the BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Fastener Notice See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the new screws (1) in the EBCM (2). Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM. 4. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the two nuts (4). 5. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 6. Return to Diagnostic System Check - ABS. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 208 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 209 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 210 Cruise Control Module (CCM) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 211 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove cruise control cable from throttle body lever. 2. Remove the cruise control cable bead (2) from the end of the ribbon (1). IMPORTANT: Do not allow the cruise control ribbon to retract into the module assembly 3. Disconnect the electrical connector from cruise module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 212 4. Remove the cruise control module bolts. 5. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module. 2. Install the cruise control module bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the cruise control module bolts to 12 N.m (106 lb in). 3. Connect the electrical connector to cruise module. 4. Install cruise control cable bead (2) to ribbon (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 213 5. Install cruise control cable to throttle body lever. 6. Perform the functional check. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The blower motor relay that is used on this vehicle is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). 2. Install the screws to the blower motor resistor assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the windshield washers and the coolant reservoir. 4. Connect the electrical connectors. 5. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 221 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center. 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair Audible Warning Device Control Module: Service and Repair MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the multifunction alarm assembly from the convenience center located under the left side of the instrument panel. 2. Release the single tab connector on the top of the assembly. 3. Pull out the single tab connector. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly to the convenience center. 2. Align the retaining tab. 3. Press the tab in place Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 233 Fuse Block - I/P Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation Interior Lighting Module: Description and Operation INTERIOR LAMPS The interior lighting consist of the following three groups. This first group includes lamps that may not be dimmed. The courtesy lamps - The stepwell lamps - The dome/reading lamps - The vanity mirror lamps - The IP compartment lamps - The driver and passenger door control switch illumination - The Rear Audio Control Illumination Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 242 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 243 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 244 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 247 Relay Box: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 248 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 249 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 250 Relay Box: Application and ID Relay Block #1 And #2 Relay Block No.1 Part 1 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 251 Relay Block No.1 Part 2 Relay Block No.2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 252 Application Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 253 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 254 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 255 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 256 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 257 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 258 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 264 Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 265 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 266 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 267 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 268 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 271 Body Control Module C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 272 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 273 Body Control Module C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 274 Body Control Module C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 275 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module C3 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 276 Body Control Module C3 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 277 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 280 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control.Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 281 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 282 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The Scan Tool 9. Perform the body control module programing. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 287 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 288 Engine Control Module: Locations Powertrain Control Module (PCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 289 Powertrain Control Module (PCM) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 292 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 293 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 294 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 295 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 296 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 297 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 298 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System Engine Control Module: Description and Operation Powertrain Control Module & the Theft Deterrent System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 301 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 302 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the symbols shown when commanded ON. The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTC's). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTC's when 40 consecutive warm-up cycles occur without a malfunction. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 303 DIAGNOSTIC TROUBLE CODES (DTC's) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTC's alert the driver via the MIL or a message. Other DTC's do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTC's are set. This data is stored in the Freeze Frame and/or Failure Records. The DTC's are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTC's and different actions taken when the DTC's set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTC's, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTC's only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTC's were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTC's will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTC's and type B DTC's (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTC's that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTC's will be listed in this category if the diagnostic has not run since DTC's were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 304 Engine Control Module: Description and Operation Distributor Ignition (DI) System The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 305 Engine Control Module: Service and Repair Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: - To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. Removal Procedure 1. Disconnect the PCM harness connectors (4). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 306 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). 3. Connect the PCM connectors (4) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure). See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 311 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 312 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 313 Ignition Control Module (ICM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 314 Ignition Control Module: Description and Operation The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 315 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations SDM, IP Module, Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 320 Left Front Interior Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 321 Left Front Interior Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 322 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 323 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 324 Air Bag Control Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 325 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 326 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). 10. Repair the fasteners using the following procedure: IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 327 mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the SDM (4) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 12 N.m (106 lb in). 5. Connect the SDM wiring harness connector (2) to the SDM (4). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the CPA (1) to the sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the sensing and diagnostic module (SDM). 9. Install the carpet retaining sill trim molding. 10. Install the driver seat. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 340 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 341 Control Module: Locations Transfer Case Shift Control Module Transfer Case Shift Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 342 Control Module: Service and Repair Transfer Case Shift Control Module REMOVAL 1. Remove the parking brake assembly mounting bolts only and lay the parking brake assembly aside. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 343 2. Remove the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 344 3. Remove the electrical connectors from the control module. 4. Remove the mounting screws for the control module. 5. Remove the control module from the mounting bracket. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 345 1. Install the control module in the mounting bracket. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct park number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the mounting screws for the control module. 3. Tighten the mounting screws to 6 Nm (53 lb.in). 4. Install the electrical connectors in the control module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 346 5. Install the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 347 6. Install the parking brake assembly. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Cruise Control Module, And Wiper Motor Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 352 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 353 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 354 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 355 Wiper Control Module: Diagrams Rear Window Wiper/Washer Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 356 Windshield Wiper Motor and Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Wiper Motor Module Replacement (Front) Wiper Control Module: Service and Repair Wiper Motor Module Replacement (Front) WIPER MOTOR MODULE REPLACEMENT (FRONT) REMOVAL PROCEDURE 1. Remove the wiper motor electrical connector. 2. Remove the cover screws. 3. Remove the cover. 4. Remove the circuit board and terminal module by lifting up on the terminal. INSTALLATION PROCEDURE 1. Install the circuit board and terminal module. 2. Install the cover and 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.6 N.m (23 lb in). 3. Install the wiper motor electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Wiper Motor Module Replacement (Front) > Page 359 Wiper Control Module: Service and Repair Wiper Motor Module Replacement (Rear) WIPER MOTOR MODULE REPLACEMENT (REAR) REMOVAL PROCEDURE 1. Remove the liftgate garnish molding. 2. Disconnect the two electrical connectors from the controller module assembly. 3. Drill the heads from the rivets with an appropriate drill bit. 4. Remove two rivets and the controller assembly from the liftgate. INSTALLATION PROCEDURE 1. Install the controller module assembly onto the liftgate. 2. Install two new rivets with a hand-held rivet gun. 3. Connect the two electrical connectors to the controller assembly. 4. Install the liftgate garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 365 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut.When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 374 Power Door Lock Switch: Diagrams Door Lock Switch - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 375 Door Lock Switch - Front Passenger Part 1 Door Lock Switch - Front Passenger Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 376 Power Door Lock Switch: Service and Repair POWER ACCESSORY SWITCH PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the armrest screws and the armrest YC5. 2. Remove the window handle, if equipped. 3. Pull out on the escutcheon in order to remove the lock lever escutcheon. Start with the front edge of the escutcheon. 4. Remove the upper corner trim using the following method: 4.1. Pull the upper corner trim at the top edge. 4.2. Pivot the upper corner trim down in order to clear the tab at the trim panel, YC6 and YC7. 5. Remove the caps that cover the screws for the assist handle. 6. Remove the screws that retain the assist handle to the door. 7. Remove the screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 2. Install the plate to the trim panel. 3. Install the screw at the front edge of the accessory switch mount plate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws at the front edge of the accessory switch mount plate to 5 N.m (44 lb in). 4. Install the assist handle and screws to the door. Tighten Tighten the assist handle screws to 5 N.m (44 lb in). 5. Install the caps that cover the screws on the assist handle. 6. Insert the tab in the slot on the door trim panel. Seat the fastener into the door at the top, YC6 and YC7 in order to install the upper corner trim. 7. Snap the lock lever escutcheon into place in order to install the lock lever escutcheon. Start at the rear edge of the escutcheon. 8. Install the window handle, if equipped. 9. Install the armrest and armrest screws, YC5. Tighten Tighten the armrest screws to 5 N.m (44 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 380 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 381 Outside Rearview Mirror Switch Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Sear - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 385 Seat - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 386 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 387 Seat Adjuster Switch - Driver Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 390 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. 3. Install the screws that retain the power seat switch to the seat. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 391 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. Installation Procedure 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 392 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the power seat switch to the seat. Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Body Wiring - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 396 Liftglass Lock/Unlock Release Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Component Locations Brake Pressure Differential Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Component Locations > Page 402 Brake Pressure Differential Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations Left Front Interior Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 406 Left Front Interior Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Left Front Interior Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 410 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 411 Notice: Refer to Fastener Notice in Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 420 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 426 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04-05-25-009 > Sep > 04 > ABS - Revised Wheel Speed Sensor Replacement Wheel Speed Sensor: All Technical Service Bulletins ABS - Revised Wheel Speed Sensor Replacement File In Section: 05 - Brakes Bulletin No.: 04-05-25-009 Date: September, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Speed Sensor Replacement Models: 2003-2004 Chevrolet Astro Van 2003-2004 GMC Safari Van This bulletin is being issued to revise the Wheel Speed Sensor Replacement in the Antilock Brake System sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information has been incorporated into the Installation steps of the Wheel Speed Sensor Replacement procedure; it does not replace that procedure. The proper installation of the wheel speed sensor (WSS) is critical to prevent corrosion from beneath the sensor. When installing a new WSS, the mounting surface must be free from any rust of corrosion. It is recommended that once the sensor is removed, the WSS bore should be plugged to prevent debris from falling into the hub. Once the WSS bore is plugged, a wire brush or equivalent should be used to clean the WSS mounting surface on the hub. After the mounting surface is free from all corrosion, apply a thin layer of wheel bearing lubricant, GM P/N 01051344 (in Canada, 993037) to the hub surface and the sensor 0-ring prior to installation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04-05-25-009 > Sep > 04 > ABS - Revised Wheel Speed Sensor Replacement Wheel Speed Sensor: All Technical Service Bulletins ABS - Revised Wheel Speed Sensor Replacement File In Section: 05 - Brakes Bulletin No.: 04-05-25-009 Date: September, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Speed Sensor Replacement Models: 2003-2004 Chevrolet Astro Van 2003-2004 GMC Safari Van This bulletin is being issued to revise the Wheel Speed Sensor Replacement in the Antilock Brake System sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information has been incorporated into the Installation steps of the Wheel Speed Sensor Replacement procedure; it does not replace that procedure. The proper installation of the wheel speed sensor (WSS) is critical to prevent corrosion from beneath the sensor. When installing a new WSS, the mounting surface must be free from any rust of corrosion. It is recommended that once the sensor is removed, the WSS bore should be plugged to prevent debris from falling into the hub. Once the WSS bore is plugged, a wire brush or equivalent should be used to clean the WSS mounting surface on the hub. After the mounting surface is free from all corrosion, apply a thin layer of wheel bearing lubricant, GM P/N 01051344 (in Canada, 993037) to the hub surface and the sensor 0-ring prior to installation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 436 ABS / Traction Control Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 437 Wheel Speed Sensor (RF & LF) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 438 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - LF Wheel Speed Sensor (WSS) - RF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 439 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (A4WD) Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2). Important: The wheel speed sensor mounts to the hub/bearing assembly. Thoroughly clean around this area in order to prevent any dirt or contaminants from entering the sealed wheel bearing. Failure to do this may lead to premature wheel bearing failure. 4. Remove the Wheel Speed Sensor (WSS) mounting bolt. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 5. Remove the wheel speed sensor (5) from the hub/bearing assembly (4). 6. Remove the WSS cable mounting clip from the knuckle. 7. Remove the WSS cable mounting clip from the upper control arm. 8. Remove the WSS cable mounting clip from the frame attachment point. 9. Remove the WSS cable electrical connector. Installation Procedure 1. Install the WSS (5) into the hub/bearing assembly (4). Notice: Refer to Fastener Notice in Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the WSS mounting bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 440 Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 3. Install the WSS cable mounting clip to the knuckle. 4. Install the WSS cable mounting clip to the upper control arm. 5. Install the WSS cable mounting clip to the frame attachment point. 6. Connect the WSS cable electrical connector. 7. Install the brake rotor (2). 8. Install the tire and wheel. 9. Return to Diagnostic Starting Point - Antilock Brake System. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Starting Point - Antilock Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 446 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 447 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Drain the coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Disconnect the electrical connector. 5. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Refer to Component Fastener Tightening Notice in Service Precautions. 1. Coat the threads with sealer GM P/N 9985253 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 448 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor harness connector to the ECT sensor. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 457 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 458 Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J 41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 462 1. Install the engine oil pressure gage sensor fitting, if removed. Tighten 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J 41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 467 Ambient Temperature Sensor / Switch HVAC: Locations Front End Center Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 468 Front End Center Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 469 Ambient Air Temperature Sensor (DIC) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 470 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the outside air temperature sensor from the center support bracket by sliding the sensor upward. 3. Disconnect the temperature sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the temperature sensor electrical connector. 2. Install the temperature sensor by sliding the sensor downward. 3. Install the radiator grille to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary Blower Motor Switch-A/C Auxiliary Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary > Page 476 Blower Motor Switch: Diagrams Blower Motor Switch - Heater Auxiliary Blower Motor Switch-Heater Auxiliary Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary > Page 477 Blower Motor Switch-Heater Auxiliary Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Auxiliary A/C BLOWER MOTOR SWITCH REPLACEMENT - AUXILIARY A/C REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary A/C blower motor switch (2) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 480 1. Install the auxiliary A/C blower motor switch (2) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 481 Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Heater Auxiliary BLOWER MOTOR SWITCH REPLACEMENT - HEATER AUXILIARY REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary heat blower motor switch (1) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 482 1. Install the auxiliary heat blower motor switch (1) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams A/C High Pressure Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 487 High Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH The A/C system is protected by two pressure switches. The A/C high pressure switch is a two wire normally open switch. The A/C high pressure switch opens the A/C request signal when the A/C line pressure exceeds 3240 kPa (470 psi) + or - 20 psi. This prevents the A/C compressor from operating. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 488 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED - J 5403 Snap Ring Pliers - J 9553-01 O-Ring Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant the system. 3. Clean the control A/C high pressure switch area before removing the snap ring. 4. Disconnect the electrical connector from the A/C high pressure switch (2) in the rear head of the compressor. 5. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. 6. Remove the A/C high pressure switch (2) from the compressor. 7. Remove the old O-ring seal from the A/C high pressure switch cavity using the J 9553-01. 8. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary. INSTALLATION PROCEDURE 1. Lubricate the new O-ring using new 525 viscosity refrigerant oil. IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring is included in a new switch kit. 2. Install the new O-ring into the groove in the switch cavity. 3. Lubricate the control switch housing using new 525 viscosity refrigerant oil. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 489 4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity. 5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove. 6. Evacuate and recharge the system. 7. Leak test the fitting(s) of the repaired or reinstalled components using the J 39400-A. 8. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 493 A/C Low Pressure Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 494 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The powertrain control module (PCM) applies the A/C low pressure switch control signal. The switch will open when the A/C low side pressure reaches 165-179 kPa (24-26 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 2282 kPa (331 psi). This allows the A/C compressor to turn back ON. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 495 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch (1) from the accumulator (3). INSTALLATION PROCEDURE 1. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the new O-ring seal to the switch. 3. Install the A/C low pressure switch (1) to the accumulator (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Headlamp and Panel Dimmer Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 503 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 504 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 505 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 506 Left Kick Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 507 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 508 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 511 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 515 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 516 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 520 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 521 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 522 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Left Front Interior Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 526 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 527 Notice: Refer to Fastener Notice in Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 532 Ambient Light Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 533 Ambient Light Sensor: Service and Repair DAYTIME RUNNING LAMPS (DRL) AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Lift upward on the center defogger grille located in center of the dash to expose the DRL photo sensor (1) retainer. 2. Turn the DRL photo sensor counterclockwise 1/4 turn in order to remove. 3. Disconnect the electrical connection from the DRL photo sensor (1). INSTALLATION PROCEDURE 1. Connect the electrical connection to the DRL photo sensor (1). 2. Insert the DRL photo sensor (1) and turn counterclockwise 1/4 turn in order to seat. 3. Install the defogger grille located in the center of the dash by push downward. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Stop Lamp Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 537 Brake Light Switch: Diagrams Stop Lamp Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 538 Tail/Stop and Turn Signal Lamp - Left Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 539 Tail/Stop and Turn Signal Lamp - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 540 Tail/Stop Lamp - Left - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 541 Tail/Stop Lamp - Right - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 542 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the battery negative cable. 2. Remove the retainer (3) from the brake pedal pin. 3. Unsnap the switch (2) and pushrod (4) from the brake pedal (1) pin. 4. Disconnect the electrical connector. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 543 1. Connect the electrical connector. 2. Install the switch (2) and pushrod (4) onto the brake pedal (1) pin. 3. Install the retainer (3) onto the brake pedal (1) pin. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Locations Dome Lamp Defeat Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 550 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 551 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 552 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 553 Left Kick Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 554 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 555 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 558 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 562 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 563 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 564 Instrument Panel Cluster (IPC) Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 565 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 566 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the instrument panel cluster trim plate. 3. Remove the switch from the plate by using the following procedure: 3.1. Release the retaining tabs on the sides of the switch. 3.2. Pull the switch out of the plate. 3.3. Disconnect the electrical connector(s) at the back of the headlamp switch. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the back of the switch. 2. Install the headlamp switch to the plate by snapping the switch into place. 3. Install the instrument panel cluster trim plate. 4. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 581 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 582 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 583 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 584 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 585 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 586 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 590 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 591 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 592 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 593 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 594 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 595 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 596 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 597 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 598 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 602 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 603 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Drain the coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Disconnect the electrical connector. 5. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Refer to Component Fastener Tightening Notice in Service Precautions. 1. Coat the threads with sealer GM P/N 9985253 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 604 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor harness connector to the ECT sensor. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 613 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 > Page 619 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 > Page 620 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 > Page 621 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set > Page 626 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 > Page 632 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 > Page 633 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls Revised DTC P0336 > Page 634 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 635 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 636 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 637 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 640 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 641 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 642 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 643 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 647 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 651 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 652 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 656 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 657 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 658 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 659 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 660 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 664 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 665 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 666 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 667 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 671 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 672 MAP, Purge Solenoid, And Throttle Body Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 673 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 674 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 675 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 676 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 677 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J 41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 681 1. Install the engine oil pressure gage sensor fitting, if removed. Tighten 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J 41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 685 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 686 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 687 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 690 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 691 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (4) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 692 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 693 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (1) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 694 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 698 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 699 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 700 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 701 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 705 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 706 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 707 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 708 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 709 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Transmission Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 Vehicle Speed Sensor (VSS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 > Page 715 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 716 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Tools Required ^ J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417. 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 721 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 722 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 723 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 724 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 725 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 726 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 730 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 731 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 732 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 733 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 738 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 739 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 740 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 741 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 742 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 743 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 744 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 745 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 746 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 755 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 761 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 762 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 763 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 768 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 774 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 775 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 776 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 777 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 778 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 779 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 782 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 783 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 784 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 785 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 789 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 790 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 791 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 792 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations SDM, IP Module, Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 797 Forward Lamps Harness, Left Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 798 Inflatable Restraint Front End Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 799 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 800 Impact Sensor: Service and Repair INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Refer to SIR Caution in Service Precautions. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Disconnect the inflatable restraint front end discriminating sensor harness connector located at the top of the frame (1). 4. Remove the bolts (2). 5. Remove the inflatable restraint front end discriminating sensor (3) from the cradle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the front end discriminating sensor horizontally to the top of the frame. 3. Point the arrow on the sensor toward the front of the vehicle. 4. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fastener to 6.5 N.m (58 lb in). 5. Perform the following steps in order to complete the first fastener repair: IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 801 5.1. Remove and discard the improperly installed rivet. 5.2. Reattach the sensor with a new rivet. 6. Perform the following steps, if needed, in order to complete a second fastener repair: 6.1. Remove the improperly installed rivet. 6.2. Enlarge the mounting holes in the lower radiator support to 9.0 mm (0.35 in). 6.3. Insert and properly seat the rivnut. 6.4. Install the screw to the sensor. Tighten Tighten fasteners to 6.5 N.m (58 lb in). 7. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 8. Lower the vehicle. Refer to Vehicle Lifting. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 813 Neutral Safety Switch: Description and Operation Park/Neutral Position Switch Description and Operation With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. With the transmission in the PARK position, the contacts in the park/neutral switch are closed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 814 Neutral Safety Switch: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 815 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 816 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 817 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Part 1 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 829 Part 2 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 834 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 835 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 836 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 837 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 841 Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 842 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 846 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 847 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 848 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 849 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 850 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 855 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 856 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 857 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 863 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 864 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 865 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 877 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 878 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 882 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 883 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 884 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 885 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 891 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 892 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 893 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 894 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 895 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 896 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 897 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 898 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 899 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 900 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 901 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 902 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 904 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 905 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 906 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 907 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 908 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 909 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 910 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 911 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 912 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 919 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 920 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 921 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 924 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 925 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 926 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 927 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 929 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 932 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 933 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 934 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 935 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 937 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 949 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 950 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 954 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 957 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 958 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 959 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 960 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Power Window Switch: Connector Views Window Master Switch - Driver C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Window Master Switch - Driver C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 963 Window Switch - Front Passenger C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 964 Window Switch - Front Passenger C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 965 Window Switch - Front Passenger C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 966 Power Window Switch: Service and Repair ACCESSORY SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Disconnect the electrical connectors. 3. Squeeze the lock tabs in order to remove the switches. INSTALLATION PROCEDURE 1. Push in on the switches in order to install the switches to the plate. 2. Connect the electrical connector. 3. Install the instrument panel cluster trim plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 971 Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 972 Rear Window Wiper/Washer Switch Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 976 Rear Window Wiper/Washer Switch Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 977 Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 978 Rear Window Wiper Washer Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 984 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 985 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 986 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 987 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 988 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 989 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 990 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications Alignment: Specifications Camber Service Allowed -1.0 to +1.0 Service Preferred 0 Cross Camber (L-R) Service Allowed -0.5 to +0.5 Service Preferred 0 Caster-Left Wheel Service Allowed 2.50 to 4.50 Service Preferred 3.5 Caster-Right Wheel Service Allowed 3.50 to 5.50 Service Preferred 4.5 Cross Caster (L-R) Service Allowed -1.5 to -0.5 Service Preferred -1.0 Steering Wheel Angle Service Allowed -6.0 to + 4.0 Service Preferred -1.0 Toe (total) Service Allowed -0.20 to + 0.20 Service Preferred 0 Z Trim Height Service Allowed 5.16 to 5.64 in Service Preferred 5.40 in D Trim Height Service Allowed 5.31 to 5.71 in Service Preferred 5.50 in Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 993 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 994 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 995 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: Tire construction - Uneven brake adjustment - Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 996 causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Remove alignment rack floating plate pins. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. 1. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and lowest measurements. Z Height Adjustment 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 999 the nut, increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage D Height Measurement The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle D heights should be within 10 mm (0.39 inch) to be considered correct. 1. Place hand on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 3. Allow the vehicle to settle into position. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. 4. Measure the D height by measuring the distance between the rear axle tube or rear axle bracket on vehicles with 7300 GVW rating and the frame. 5. Repeat the jouncing operation 2 more times for a total of 3 times. 6. Use the highest and lowest measurements to calculate the average height. 7. The true D height dimension is the average of the highest and the lowest measurements. 8. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear leaf springs. ^ Worn rear suspension components, such as leaf spring bushings. ^ Collision damage Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1000 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: Inspect the tires for the proper inflation and irregular tire wear. - Inspect the runout of the wheels and the tires. - Inspect the wheel bearings for backlash and excessive play. - Inspect the ball joints and tie rod ends for looseness or wear. - Inspect the control arms and stabilizer shaft for looseness or wear. - Inspect the steering gear for looseness at the frame. - Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. - Inspect the vehicle trim height. - Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. - Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1001 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and the camber angles, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - When checking the left and the right side caster, the right side minus the left side must be equal within 0 degrees to 2.0 degrees. - When setting the left and the right side caster, the right side minus the left side must be equal within 0.50 degrees to 1.50 degrees. - When checking the camber, it must be equal within 1.0 degrees. - When setting the camber, it must be equal within 0.50 degrees. - The caster and the camber set is relative to the ground. Important: When this camber adjustment is followed, the caster setting will not be affected. 1. If the camber is not within specifications, adjust the camber using the following procedure: 1.1. Hold the cam bolt (6) and loosen the nut (2). 1.2. Rotate the cam (1) by rotating the bolt head (6). Turn the cam bolt in order to obtain change equal to 4/2 of the needed correction. 1.3. Hold the cam bolt (6) in this position in order to maintain the setting. 1.4. Obtain the remaining 1/2 of the needed correction by repeating steps 1 through 3 to the other cam bolt. Turn the cam lobe in the same direction. 2. If the caster is not within specifications, adjust the caster using the following procedure: 2.1. Note the camber reading. 2.2. Hold the front cam bolt (6) and loosen the nut (2). 2.3. Turn the front cam bolt in order to obtain a change equal to 1/4 of the desired caster change. At the front cam bolt, a positive camber change produces a positive caster change and a negative camber change produces a negative caster change. 2.4. Hold the cam bolt (6) in this position while tightening the nut (2) in order to maintain setting. 2.5. Hold the rear cam bolt (6) and loosen the nut (2). 2.6. In order to return the camber to the setting that you noted earlier, turn the cam bolt (6) by turning the cam lobe (1) in the opposite direction. 2.7. Check the caster setting. Repeat the above procedure if not within specifications Notice: Refer to Fastener Notice in Service Precautions. 2.8. When adjustments are complete, hold the cam bolt (6) head in order to ensure the cam position does not change while tightening the upper control arm mounting nut. - Tighten the upper control arm mounting nut to 140 Nm (103 ft. lbs.). Front Wheel Toe Adjustment Front Toe Adjustment The toe-in can be increased or decreased by changing the length of the tie rods. A threaded sleeve is provided for this purpose. When the tie rods are mounted ahead of the steering knuckle, the tie rods must be modified as follows: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1002 - Decreased in length in order to increase the toe-in. Increased in length in order to decrease the toe-in. Important: When checking and setting the toe-in, the left and right side to be set separately and the steering wheel must be held straight ahead position within 4 - 6 degrees. Before adjusting the toe-in, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Adjust the toe-in with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - For an accurate toe-in reading, do not push or pull on the tires during the alignment process. 1. Set the steering wheel in the straight ahead position. 2. Loosen the clamp bolts at each end of the steering tie rod adjustable sleeves. Important: The tie rod adjuster often becomes rusted in service. 3. If the torque needed to rotate the adjuster tube exceeds 9 Nm (80 inch lbs.), perform the following steps: 3.1. Remove the adjuster tube clamp nuts and the bolts. Discard the nuts and the bolts. 3.2. Apply the penetrating oil between the adjuster tube and the tie rod threads. 3.3. Rotate the adjuster tube until the tube moves freely. 3.4. Install the new bolts and the nuts with the correct part number. The nut must be towards the front of the vehicle. 4. Rotate the inner and the outer tie rod sockets rearward to the limit of the ball stud travel. 5. Turn the tie rod adjusting sleeves to set the toe-in to specifications. Notice: Refer to Fastener Notice in Service Precautions. Important: Before tightening the adjuster tube nuts, do the following: Check the number of threads on each tie rod within the adjuster tube. The tie rod threads within the adjuster tube must be equal to within 3 threads. - Check the relationship of the adjuster tube to the clamp. The adjuster tube slot and the clamp opening must not be in the same position. The position of the adjuster tube clamp must not exceed 30 degrees in either direction. - The adjuster tube clamp must be on the inside of the adjuster tube dimple. 6. Tighten the adjuster tube clamp nuts. - Tighten the adjuster tube clamp nuts to 25 Nm (18 ft. lbs.). The clamp ends may touch when the nuts are tightened to specification. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1003 7. Rotate the tie rod sockets to the centered position. Ensure that the outer socket is square with the stud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1009 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1010 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1011 Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1012 Steps 4-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1013 Step 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1014 Steps 9-12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1015 Steps 13-14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1016 Steps 15-18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1017 Steps 19-23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1030 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1036 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-06-04-077 > Dec > 05 > Engine Controls - Lack of Power When Hot PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Lack of Power When Hot Bulletin No.: 05-06-04-077 Date: December 22, 2005 TECHNICAL Subject: Lack of Power (LU3 Engine) at High Ambient Temperatures Only (If Necessary, Reprogram PCM with New Service Calibration) Models: 2003-2005 Chevrolet Astro, Blazer, Express, S-10, Silverado 2003-2005 GMC Jimmy, Safari, Savana, Sierra, Sonoma with 4.3L Vortec(TM) V6 Engine (VIN X - RPO LU3) Condition Some customers may comment that the vehicle may exhibit a lack of power at high ambient temperatures. Cause Engineering has identified a concern with the PCM software. In high ambient temperatures, the engine control management system may falsely retard the timing, causing a noticeable loss of power. Correction Important: Before Reprogramming the PCM, verify the customer concern. Refer to SI Engine Controls and under Diagnostic Information and Procedures. Refer to Lack of Power, Sluggishness, or Sponginess for the cause of the low power condition at high ambient temperatures. If no trouble is found, then reprogram the PCM. Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 12.5, which was broadcast to dealers on 12/11/2005. For the dealerships that use CDs, the CD version will be 1.0 for 2006, which will be mailed 0111212006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate > Page 1046 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate > Page 1056 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1057 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1063 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1064 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1068 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots 1/2 turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-041A > Jan > 05 > Ignition System SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-041A > Jan > 05 > Ignition System SES Lamp ON/Misfire/DTC P0300 > Page 1077 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-04-041A > Jan > 05 > Ignition System SES Lamp ON/Misfire/DTC P0300 > Page 1078 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 1084 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 1085 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Distributor: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Distributor: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1091 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Distributor: > 04-03-10-004 > May > 04 > Wheels - Wheel Fastener Torque Specification Update Wheel Fastener: All Technical Service Bulletins Wheels - Wheel Fastener Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 04-03-10-004 Date: May, 2004 SERVICE MANUAL UPDATE Subject: Revised Tire and Wheel Removal and Installation Fastener Tightening Specification Models: 2003 Chevrolet Astro Van 2003 GMC Safari Van This bulletin is being issued to revise the fastener tightening specification in the Tire and Wheel Removal and Installation procedure in the Tires and Wheels sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct tightening specification for the wheel nuts (Step 2 of Installation) is 190 N.m (140 lb ft). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Distributor: > 02-03-10-008 > Dec > 02 > Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Distributor: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1105 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Page 1114 Distributor: Testing and Inspection DISTRIBUTOR INSPECTION 1. Remove the engine cover. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 2. Remove the 2 screws from the rotor. 3. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1117 4. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 5. Line up the square-cut hole in the vane wheel with the CMP sensor. 6. Remove the 2 screws that hold the camshaft position (CMP) sensor. 7. Discard the screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1118 8. Remove the CMP sensor. 9. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 10. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 11. Drive out the roll pin with a suitable punch. 12. Remove the driven gear from the distributor shaft. 13. Remove the round washer. 14. Remove the tang washer. 15. Remove the shim washer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1119 16. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Insert the sensor into the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1120 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1121 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1122 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1123 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. - Twist each spark plug wire 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1124 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1125 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1126 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1127 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 15. Install the engine cover. INSTALLATION PROCEDURE 2 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1128 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 2. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1129 3. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. 4. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 5. Install the distributor cap. 6. Install the new distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1130 Tighten Tighten the screws to 2.4 N.m (21 lb in). 7. Install the electrical connector to the distributor. 8. Install the spark plug wires to the distributor cap. 9. Install the ignition coil wire. Note the correct orientation of the wire boot. 10. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 11. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug: Electrical Specifications Spark Plug Wire Resistance................................................................................................................. ........................................................1,000 ohms per ft Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1135 Spark Plug: Mechanical Specifications Spark Plug Gap 0.060 in. 1.52 mm Spark Plug Torque Used Heads 15 Nm 11 lb. ft. New Aluminum Heads 20 Nm 15 lb. ft. New Iron Heads 30 Nm 22 lb. ft. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1136 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ....................................................... AC Type 41-932 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1137 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1138 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1139 - Incorrect combustion - Reduced ignition system voltage output - Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1140 Spark Plug: Service and Repair REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.524 mm (0.060 in). 3. Hand start the spark plugs in the corresponding cylinders. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plugs. Tighten For used heads tighten the spark plugs to 15 N.m (11 lb ft). - For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). - For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 1. Install the spark plug wires. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1144 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml. (1 oz.) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1152 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1153 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1154 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > With Air Conditioning With A/C Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > With Air Conditioning > Page 1157 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1158 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Steps 1-15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of rubber dust. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1161 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation procedure. 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1162 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Steps 1-6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1163 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Steps 1-12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1164 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Steps 1-8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1165 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Steps 1-15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1166 rubber dust. 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation procedure. 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Steps 1-6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1167 Steps 1-12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1168 Steps 1-8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1169 Steps 1-9 Diagnostic Aids A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent verify the accessory drive components by varying their loads. Ensure the accessory components are operated to their maximum capacity. An overcharged A/C system or power steering system with: a pinched hose, an incorrect fluid, or a failed generator are suggested items to inspect. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt or an accessory drive component. If the drive belt is removed, the water pump may not operate. Without the water pump the engine may overheat. DTCs may set when the engine is operating with the drive belt removed. 4. This test verifies that an accessory drive component does not have a seized bearing. Remove the belt and test the bearings for smooth turning in the accessory drive components. Test the accessory drive components with the engine operating, vary the load on the components to verify that the components operate correctly. 5. This test is to verify that the drive belt tensioner operates correctly. If the drive belt tensioner is not operating correctly, correct belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working correctly. Also if an incorrect length drive belt was installed, it may not be routed correctly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a pulley that is incorrectly aligned using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1170 Steps 1-11 Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1171 Steps 1-5 Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. DTCs may set if the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the correct inspection and replacement procedure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1172 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the air cleaner outlet duct from the throttle body. 3. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 4. Remove the drive belt. 5. Slowly release the tension on the drive belt tensioner arm. Installation Procedure 1. Route the belt over all the pulleys except the tensioner arm. 2. Observe drive belt routing for vehicles without air conditioning. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1173 3. Observe drive belt routing for vehicles with air conditioning. 4. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 5. Install the drive belt over the drive belt tensioner pulley. 6. Slowly release the tension on the tensioner arm. 7. Inspect for the drive belt being properly installed on the pulleys. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1174 8. Avoid mis-positioning the drive belt by one or more grooves. 9. Confirm for the proper drive belt size and the correct drive belt routing by observing the location of the fix pointer and the index marks on the drive belt tensioner. With a new drive belt installed, the fix pointer should align within the indentation on the drive belt tensioner. 10. With a used drive belt installed, the fix pointer should not align past the index mark. 11. Install the air cleaner outlet duct. 12. Install the air cleaner assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 1185 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1191 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1192 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1196 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1197 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1198 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant; GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1204 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1205 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 1209 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Note the position of the fuel strainer (2) on the fuel sender. 3. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand. 4. Pull the strainer off the fuel sender. Discard the strainer after inspection. 5. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank. INSTALLATION PROCEDURE 1. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated. 2. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1214 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil in a suitable container. 3. Remove the engine oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the engine oil filter gasket with clean engine oil. 2. Install the engine oil filter. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1215 3. Follow the tightening instructions on the oil filter. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the drain plug to the oil pan. ^ Tighten the oil pan plug to 25 Nm (18 ft. lbs.). 5. Remove the safety stands and lower the vehicle. 6. Fill the engine with the proper capacity and quality of engine oil. 7. Operate the engine, check for leaks and oil pressure. 8. Check the oil level and add as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the evaporator tube (1) from the vehicle. 2. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. 4. Using a tubing cutter, cut the marked section of the evaporator tube (1). IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 5. Remove the burrs from the evaporator tube (1). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. IMPORTANT: DO NOT install the O-rings (2) in this step. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 1220 9. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing toward the evaporator. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 1221 15. Install the evaporator tube (1) to the vehicle. 16. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 1222 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Remove the air cleaner. 3. Remove the coolant recovery reservoir. 4. Loosen the nuts (4) from the A/C refrigerant filter (1). IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 5. Remove the A/C refrigerant filter from the evaporator tube (1). INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 1223 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter to the evaporator tube (1) with the flow arrow pointing toward the evaporator. 3. Tighten the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Evacuate and recharge the A/C system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 1224 5. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 6. Install the coolant recovery reservoir. 7. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement Coolant Line/Hose: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Place a drain pan under the oil filter adapter. 2. Remove the engine oil cooler lines mounting bolt from the oil filter adapter assembly. 3. Remove the engine oil cooler lines from the oil filter assembly. 4. Remove the engine oil cooler line to engine bracket bolt. 5. Remove the engine oil cooler lines from the engine bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 1230 6. Remove the oil cooler lines from the radiator. 7. Remove the engine oil cooler lines. 8. Clean all of the components with a suitable solvent. Dry the components with compressed air. 9. Inspect the following for damage or distortion: ^ The connector fittings ^ The connectors ^ The engine oil cooler lines Installation Procedure Important: Inspect the cooler line for a damaged or missing plastic cap. If the plastic cap is damaged or missing, replace it with a new plastic cap. 1. Install the engine oil cooler lines. 2. Install the engine oil cooler lines. 3. Install the engine oil cooler lines to the engine bracket. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the engine oil cooler line bracket bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 1231 5. Install the engine oil cooler lines to the oil filter adapter assembly. 6. Install the engine oil cooler line bolt to the oil filter assembly. ^ Tighten the oil cooler lines to oil filter adapter assembly bolt to 35 Nm (26 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 1232 Coolant Line/Hose: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 3. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors. 4. Clean all of the components in a suitable solvent, and dry them with compressed air. 5. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 1233 1. Install a new retaining ring into each quick connector fitting. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 1234 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. 6. Inspect and fill the engine oil to the proper level. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet Heater Hose: Service and Repair Heating Hoses Replacement - Inlet HEATING HOSES REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. 3. Remove the coolant recovery reservoir. 4. Remove the heater hose support clamp bolt (5). 5. Using the J 38185, reposition the inlet heater hose clamp from the heater core. 6. Remove the inlet heater hose (2) from the heater core. 7. Using the J 38185, reposition the inlet heater hose clamp from the water valve. 8. Remove the inlet heater hose (2) from the water bypass valve. INSTALLATION PROCEDURE 1. Install the inlet heater hose (2) to the water bypass valve. 2. Using the J 38185, reposition the inlet heater hose clamp to the water bypass valve. 3. Install the inlet heater hose (2) to the heater core. 4. Using the J 38185, reposition the inlet heater hose clamp to the heater core. 5. Install the heater hose support clamp to the heater core. 6. Install the heater hose support clamp bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 1239 Tighten Tighten the bolt to 4 N.m (35 lb in). 7. Install the coolant recovery reservoir. 8. Fill the cooling system. 9. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 1240 Heater Hose: Service and Repair Heating Hoses Replacement - Outlet HEATING HOSES REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. 3. Remove the coolant recovery reservoir. 4. Remove the heater hose support clamp bolt (5). 5. Using the J 38185, reposition the outlet heater hose clamp from the heater core. 6. Remove the outlet heater hose (3) from the heater core. 7. Using the J 38185, reposition the outlet heater hose clamp from the water bypass valve. 8. Remove the outlet heater hose (3) from the water bypass valve. INSTALLATION PROCEDURE 1. Install the outlet heater hose (3) to the water bypass valve. 2. Using the J 38185, reposition the outlet heater hose clamp to the water bypass valve. 3. Install the outlet heater hose (3) to the heater core. 4. Using the J 38185, reposition the outlet heater hose clamp to the heater core. 5. Install the heater hose support clamp to the heater core. 6. Install the heater hose support bolt (5). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 1241 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 7. Install the coolant recovery reservoir. 8. Fill the cooling system. 9. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 1242 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Front HEATER PIPE REPLACEMENT - AUXILIARY FRONT REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the front pipes (5) from the rear pipes. 4. Remove the bolts (3) that retain the front pipes (5) to the body. 5. Remove the clips (4) that retain the front pipes (5) to the body. 6. Remove the auxiliary heater front pipes (5) from the heater hoses (1). 7. Remove the auxiliary heater front pipes (5). INSTALLATION PROCEDURE 1. Install the auxiliary heater front pipes (5). 2. Connect the auxiliary heater front pipes (5) to the heater hoses (1). 3. Install the front pipe retaining clips (4) that retains the front pipes (5) to the body. 4. Install the bolts (3) that retain the front pipes (5) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the auxiliary heater front pipes (5) to the rear pipes. 6. Fill the cooling system with engine coolant. 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 1243 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Rear HEATER PIPE REPLACEMENT - AUXILIARY REAR REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Raise the vehicle.Refer to Vehicle Lifting. 3. Disconnect the auxiliary heater rear pipes from the heater core inlet and outlet tubes. 4. Disconnect the auxiliary heater rear pipes from the front pipes. 5. Remove the pipe retainers from the body. 6. Remove the auxiliary heater rear pipes. INSTALLATION PROCEDURE 1. Install the auxiliary heater rear pipes. 2. Install the pipe retainers to the body. 3. Connect the auxiliary heater rear pipes to the front pipes. 4. Connect the rear pipes to the auxiliary heater core inlet and outlet tubes. 5. Refill the cooling system with engine coolant. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Remove the grille. 4. Remove the engine cover. 5. Remove the compressor hose assembly bolt (2). 6. Remove the compressor hose assembly from the compressor. 7. Remove and discard the old sealing washers. 8. Remove the hose clamp bracket nut (3) from the engine stud. 9. Loosen the compressor hose assembly nut (6) from the condenser. 10. Remove the compressor hose assembly nut (1) from the accumulator. 11. Remove the bolt from the transmission filler tube to the oil indicator tube. 12. Remove transmission filler tube from the throttle cable bracket. 13. Remove the compressor hose assembly from the vehicle. 14. Cap or plug all open connections on the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1248 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. 4. Install the bolt to the transmission filler tube to the oil indicator tube. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 12 N.m (106 lb in). 5. Install new O-rings. 6. Install the compressor hose assembly to the accumulator. 7. Tighten the compressor hose assembly nut at the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 8. Install new O-rings. 9. Install the compressor hose assembly to the condenser. 10. Tighten the compressor hose assembly nut (6). Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 12. Install new sealing washers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1249 13. Install the compressor hose assembly to the compressor. 14. Tighten the compressor hose assembly bolt. Tighten Tighten the bolt to 34 N.m (25 lb ft). 15. Install the engine cover. 16. Install the grille. 17. Evacuate and recharge the system. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1250 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code C60) EVAPORATOR TUBE REPLACEMENT (WITH RPO CODE C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Loosen the evaporator tube nut at the evaporator. 4. Remove the evaporator tube (2) from the evaporator. 5. Remove the O-ring seal. 6. Remove the grille. 7. Loosen the evaporator tube nut at the condenser. 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1251 Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. 7. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1252 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code C69) EVAPORATOR TUBE REPLACEMENT ((WITH RPO CODE C69) TOOLS REQUIRED - J 38778 Door Trim Pad and Garnish Clip Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the accumulator. 3. Remove the grille. 4. Loosen the evaporator tube nut at the evaporator. 5. Remove the evaporator tube (2) from the evaporator. 6. Remove the O-ring seal. 7. Loosen the evaporator tube nut at the condenser. 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. 10. Remove the right front tire. 11. Use the J 38778 to remove the retainers from the splash shield. 12. Remove the splash shield from the wheelhouse. 13. Remove the nut at the auxiliary evaporator tube block fitting. 14. Remove the evaporator tube from the auxiliary evaporator tube. 15. Remove the O-ring seal. 16. Lower the vehicle. 17. Remove the evaporator tube. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1253 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the new O-ring seal. 5. Install the evaporator tube to the evaporator. 6. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Raise the vehicle.Refer to Vehicle Lifting. 8. Install the new O-ring seal. 9. Install the evaporator tube to the auxiliary evaporator tube. 10. Install the auxiliary evaporator tube block fitting nut. Tighten Tighten the nut to 28 N.m (20 lb ft). 11. Install the splash shield to the wheelhouse. 12. Install the retainers to the splash shield. 13. Install the right front tire. 14. Install the accumulator. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the grille. 17. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1254 Hose/Line HVAC: Service and Repair Accumulator Tube Replacement - Auxiliary Side ACCUMULATOR TUBE REPLACEMENT - AUXILIARY SIDE TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1255 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1256 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1257 Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Remove the grille. 4. Remove the engine cover. 5. Remove the compressor hose assembly bolt (2). 6. Remove the compressor hose assembly from the compressor. 7. Remove and discard the old sealing washers. 8. Remove the hose clamp bracket nut (3) from the engine stud. 9. Loosen the compressor hose assembly nut (6) from the condenser. 10. Remove the compressor hose assembly nut (1) from the accumulator. 11. Remove the bolt from the transmission filler tube to the oil indicator tube. 12. Remove transmission filler tube from the throttle cable bracket. 13. Remove the compressor hose assembly from the vehicle. 14. Cap or plug all open connections on the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1258 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. 4. Install the bolt to the transmission filler tube to the oil indicator tube. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 12 N.m (106 lb in). 5. Install new O-rings. 6. Install the compressor hose assembly to the accumulator. 7. Tighten the compressor hose assembly nut at the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 8. Install new O-rings. 9. Install the compressor hose assembly to the condenser. 10. Tighten the compressor hose assembly nut (6). Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 12. Install new sealing washers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1259 13. Install the compressor hose assembly to the compressor. 14. Tighten the compressor hose assembly bolt. Tighten Tighten the bolt to 34 N.m (25 lb ft). 15. Install the engine cover. 16. Install the grille. 17. Evacuate and recharge the system. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Evaporator Tube Replacement (With RPO Code C60) EVAPORATOR TUBE REPLACEMENT (WITH RPO CODE C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Loosen the evaporator tube nut at the evaporator. 4. Remove the evaporator tube (2) from the evaporator. 5. Remove the O-ring seal. 6. Remove the grille. 7. Loosen the evaporator tube nut at the condenser. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1260 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. 7. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Evaporator Tube Replacement (With RPO Code C69) EVAPORATOR TUBE REPLACEMENT ((WITH RPO CODE C69) TOOLS REQUIRED - J 38778 Door Trim Pad and Garnish Clip Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the accumulator. 3. Remove the grille. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1261 4. Loosen the evaporator tube nut at the evaporator. 5. Remove the evaporator tube (2) from the evaporator. 6. Remove the O-ring seal. 7. Loosen the evaporator tube nut at the condenser. 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. 10. Remove the right front tire. 11. Use the J 38778 to remove the retainers from the splash shield. 12. Remove the splash shield from the wheelhouse. 13. Remove the nut at the auxiliary evaporator tube block fitting. 14. Remove the evaporator tube from the auxiliary evaporator tube. 15. Remove the O-ring seal. 16. Lower the vehicle. 17. Remove the evaporator tube. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the new O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1262 5. Install the evaporator tube to the evaporator. 6. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Raise the vehicle.Refer to Vehicle Lifting. 8. Install the new O-ring seal. 9. Install the evaporator tube to the auxiliary evaporator tube. 10. Install the auxiliary evaporator tube block fitting nut. Tighten Tighten the nut to 28 N.m (20 lb ft). 11. Install the splash shield to the wheelhouse. 12. Install the retainers to the splash shield. 13. Install the right front tire. 14. Install the accumulator. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the grille. 17. Install the air cleaner. Accumulator Tube Replacement - Auxiliary Side ACCUMULATOR TUBE REPLACEMENT - AUXILIARY SIDE TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1263 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1264 Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. Compressor/Condenser Hose Replacement - Auxiliary COMPRESSOR/CONDENSER HOSE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 39400-A Halogen Leak Detector Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1265 REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant. 3. Remove the grille. 4. Remove the engine cover. 5. Raise the vehicle.Refer to Vehicle Lifting. 6. Disconnect the auxiliary evaporator lines nut from the compressor hose assembly. 7. Lower vehicle. 8. Remove the nut that attaches the compressor hose assembly bracket to the engine. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1266 9. Remove the hose clamp bracket nut (3) from the engine stud. 10. Remove the compressor hose assembly bolt from the compressor. 11. Remove the sealing washers from the compressor. 12. Remove the compressor hose assembly nut (6) from the condenser. 13. Remove the compressor hose assembly nut (1) from the accumulator. 14. Remove the compressor hose assembly from the vehicle. 15. Cap or plug all open connections. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1267 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install the compressor hose assembly nut (1) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 48 N.m (35 lb ft). 4. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Install new seal washers to the compressor. 6. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1268 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the nut that attaches the compressor hose assembly bracket to the engine. Tighten Tighten the nut to 5 N.m (44 lb in). 9. Raise the vehicle.Refer to Vehicle Lifting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1269 10. Connect the auxiliary evaporator hose nut to the compressor hose assembly. Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Lower the vehicle. 12. Install the engine cover. 13. Install the grille. 14. Evacuate and recharge the system. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the air cleaner. Evaporator Tube Replacement - Auxiliary Front EVAPORATOR TUBE REPLACEMENT - AUXILIARY FRONT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator front inlet tube from the evaporator inlet tube (2) at the accumulator. 4. Remove the O-ring seal. 5. Remove the bolts (3) that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. 6. Remove the auxiliary evaporator front inlet tube (2) from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1270 1. Install the auxiliary evaporator front inlet tube (2) to the vehicle. 2. Install the bolts that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. 4. Install the auxiliary evaporator front inlet tube (2) to the auxiliary evaporator side inlet tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Lower the vehicle. 6. Evacuate and recharge the system. 7. Leak test the fittings of the component using the J 39400-A. Evaporator Tube Replacement - Auxiliary Rear EVAPORATOR TUBE REPLACEMENT - AUXILIARY REAR TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1271 3. Remove the auxiliary evaporator rear outlet tube from the auxiliary evaporator outlet side tubes. 4. Remove the auxiliary evaporator rear inlet tube from the auxiliary evaporator inlet side tubes. 5. Remove the bolts that retain the clips on the tubes to the body. 6. Remove the nut that retains the tube to the auxiliary evaporator module. 7. Remove the tube from the auxiliary evaporator module. 8. Remove the seal washers. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1272 1. Install the seal washers. 2. Install the tube to the auxiliary evaporator module. 3. Install the nut that retains the tube to the auxiliary evaporator module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 25 N.m (18 lb ft). 4. Install the bolts that retain the clips on the tubes to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Install the auxiliary evaporator rear tube inlet tube to the auxiliary evaporator inlet side tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 6. Install the auxiliary evaporator rear tube outlet tube to the auxiliary evaporator outlet side tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1273 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Evaporator Tube Replacement - Auxiliary Side EVAPORATOR TUBE REPLACEMENT - AUXILIARY SIDE TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator rear tube (3). 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator front tube (2). 6. Remove the O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1274 7. Remove the bolts (1) that retain the clips on the auxiliary side inlet tube (3) to the body. 8. Remove the auxiliary evaporator side inlet tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator side inlet tube (3) to the vehicle. 2. Install the bolts that retain the clips on the auxiliary evaporator side inlet tube (3) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1275 4. Install the auxiliary evaporator side inlet tube to the auxiliary evaporator front inlet tube (2). Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. 6. Install the auxiliary evaporator side inlet tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. Suction Screen Installation SUCTION SCREEN INSTALLATION TOOL REQUIRED J 44551 Suction Screen Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1276 1. Insert J 44551 -6 sizing tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel (1) to J 44551 -5. 4. Install the J 44551 -5 screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551 -5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. IMPORTANT: Correct placement of J 44551 -5 is critical. 6. Remove the J 44551 -5 suction screen tool from the suction hose. 7. Install an A/C refrigerant filter. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1277 IMPORTANT: After a major compressor failure, you should also install an A/C refrigerant filter. 8. Install the J 44551 -1 suction screen notification label. Suction Screen Replacement SUCTION SCREEN REPLACEMENT TOOLS REQUIRED - J 42220 Universal Leak Detection Lamp - J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. 2. Remove the engine cover. 3. Remove the A/C compressor hose assembly bolt. 4. Separate the A/C compressor hose assembly from the A/C compressor. 5. Select the proper size removal tool (1) from J 44551. IMPORTANT: The suction screens are available in 3 different sizes. 6. Remove the suction screen using the J 44551-31 suction screen removal tool. 6.1. Thread the forcing screw into the suction screen. 6.2. Tighten the nut on the forcing screw to remove the suction screen. INSTALLATION PROCEDURE 1. Insert the J 44551-6 sizing tool (1) into the suction hose to select the correct size suction screen. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1278 2. Insert the suction screen into the suction hose. 3. Install the J 44551-3 mandrel (1) to J 44551-5. 4. Install the J 44551-5 suction screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551-5.The suction screen is fully installed when the screen is flush with the end of the suction hose. IMPORTANT: Correct placement of J 44551-5 is critical. 6. Remove the J 44551-5 suction screen tool from the suction hose. 7. Replace the seal washers. 8. Install the A/C compressor hose assembly to the A/C compressor. 9. Install the A/C compressor hose assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 34 N.m(25 lb ft). 10. Evacuate and recharge the A/C system. 11. Leak test the fittings of the component using J 42220. 12. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight Power Steering Line/Hose: Customer Interest Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight > Page 1287 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering Whistle Noise When Driving Straight Power Steering Line/Hose: All Technical Service Bulletins Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering Whistle Noise When Driving Straight > Page 1293 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1294 Power Steering Line/Hose: Specifications Power Steering Hose Fittings 20 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement Power Steering Line/Hose: Service and Repair P/S Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement Removal Procedure 1. Disconnect the power steering cooler hose from the steering pump. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Install a drain pan under the vehicle. 4. Disconnect the power steering cooler pipe hose from the steering gear. 5. Remove the power steering cooler pipe (2) from the air baffle (3). 6. Remove the power steering cooler pipe from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1297 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe (2) to the air baffle (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the power steering cooler pipe to the steering gear. - Tighten the power steering cooler pipe to the steering gear to 27 Nm (20 ft. lbs.). 4. Lower the vehicle. 5. Connect the power steering cooler hose to the steering pump. 6. Bleed the power steering system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1298 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the hydraulic brake booster inlet hose from the of the power steering pump. 3. Lower the vehicle. 4. Disconnect the hydraulic brake booster inlet hose from the hydraulic brake booster. 5. Remove the hydraulic brake booster inlet hose from vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1299 1. Install the hydraulic brake booster inlet hose to vehicle. 2. Connect the hydraulic brake booster inlet hose to the hydraulic brake booster. 3. Raise the vehicle. Refer to Vehicle Lifting. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the hydraulic brake booster inlet hose to the power steering pump. - Tighten the hydraulic brake booster inlet hose to the power steering pump to 27 Nm (20 ft. lbs.). 5. Bleed the system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1300 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure Important: Note the position of all the tie-straps, power steering hoses and the hose insulators for proper re-installation. 1. Remove the power brake booster outlet hose tie-straps. 2. Place a drain pan under the vehicle. 3. Disconnect the power steering cooler hose from the power steering gear. 4. Disconnect the hydraulic brake booster outlet hose from the steering gear. 5. Disconnect the hydraulic brake booster outlet hose from the hydraulic brake booster. 6. Remove the hydraulic brake booster outlet hose from the vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1301 1. Install the hydraulic brake booster outlet hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the hydraulic brake booster outlet hose to the hydraulic brake booster. - Tighten the hydraulic brake booster outlet hose to the hydraulic brake booster to 27 Nm (20 ft. lbs.). 3. Connect the hydraulic brake booster outlet hose to the power steering gear. - Tighten the hydraulic brake booster outlet hose to the power steering gear to 27 Nm (20 ft. lbs.). 4. Remove the drain pan. 5. Install the hydraulic brake booster outlet hose tie straps. 6. Bleed the system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Using the J 38185 reposition the radiator inlet hose clamp from the radiator. 4. Using the J 38185 reposition the radiator inlet hose clamp from the thermostat housing. 5. Remove the radiator inlet hose. Installation Procedure 1. Install the radiator inlet hose to the thermostat housing. 2. Using the J 38185 reposition the radiator inlet hose clamp to the thermostat housing. 3. Install the radiator inlet hose to the radiator. 4. Using the J 38185 reposition the radiator inlet hose clamp to the radiator. 5. Install the air cleaner assembly. 6. Fill the cooling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 1306 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Using the J 38185 reposition the radiator outlet hose clamp from the radiator. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Using the J 38185 reposition the radiator outlet hose clamp from the water pump. 6. Remove the outlet hose. Installation Procedure 1. Install the radiator outlet hose to the water pump. 2. Using the J 38185 reposition the radiator outlet hose clamp to the water pump. 3. Lower the vehicle. Refer to Vehicle Lifting. 4. Install the radiator outlet hose to radiator. 5. Using the J 38185 reposition the radiator outlet hose clamp to the radiator. 6. Install the air cleaner assembly. 7. Fill the cooling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Delco Supreme II .............................................................................................................................................. GM P/N 12377967 (Canadian P/N 992667) - or equivalent DOT-3 brake fluid CAUTION: The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information Brake Fluid Irritant Caution CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: ^ Eye Contact - rinse thoroughly with water. ^ Skin Contact - wash with soap and water. ^ If Ingested - consult a physician immediately. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 1313 Brake Fluid: Vehicle Damage Warnings Brake Fluid Effects on Paint and Electrical Components Notice NOTICE: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces., immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables. use a clean shop cloth to wipe away the fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1318 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1319 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1320 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1321 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications With Rear Heater 16.5 qt (US) Note: Recheck fluid level after filling system. W/O Rear Heater 13.5 qt (US) Note: Recheck fluid level after filling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1324 Coolant: Fluid Type Specifications Engine Coolant 50/50 mixture of clean, drinkable water and use only GM Goodwrench DEX-COOL or Havoline DEX-COOL Coolant. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1329 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1330 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1331 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1332 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1335 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1336 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1337 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1338 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1339 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant; GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 1344 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Axle ............................................................................................................................................ ................................................. 1.2 Liters (2.6 Pints) Rear Axle (Standard) ........................................ ..................................................................................................................................... 1.7 Liters (3.5 Pints) Rear Axle (Locking) ................................................................................................................... ........................................................... 1.7 Liters (3.5 Pints) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1347 Fluid - Differential: Fluid Type Specifications Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Rear Differential Differential Fluid Type Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle Fluid - Differential: Service and Repair Front Drive Axle Lubricant Change Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fill plug and the washer. 3. Remove the drain plug and the washer. 4. Drain the fluid from the front axle differential. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 1350 1. Install the drain plug and the washer. Tighten the drain plug to 33 Nm (24 ft. lbs.). 2. Fill the front differential with lubricant. Use the proper fluid. 3. Install the fill plug and the washer. Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 1351 Fluid - Differential: Service and Repair Rear Drive Axle Lubricant Level Check Lubricant Level Check 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. Specification The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. Lubricant Change Lubricant Change Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 1352 3. Remove the rear axle housing cover and the rear axle housing cover gasket. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Install the new rear axle housing cover gasket and the rear axle housing cover. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear axle housing cover bolts. Tighten the rear axle housing cover bolts to 30 Nm (22 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 1353 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns Fluid - Transfer Case: Customer Interest Drivetrain - Transfer Case Shudder On Tight Turns Bulletin No.: 99-04-21-005E Date: November 28, 2005 TECHNICAL Subject: Transfer Case Shudder (Flush and Replace Transfer Case Fluid) Models: 1999-2005 Chevrolet Astro (AWD) 1999-2005 GMC Safari (AWD) 1999-2001 Oldsmobile Bravada with All-Wheel Drive (NV 136) Transfer Case (RPO NP4) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 99-04-21-005D (Section 04 - Driveline/Axle). Condition Some customers may comment on a vibration (shudder) during tight turning maneuvers on dry pavement at vehicle speeds less than 8 km/h (5 mph). Cause This condition may be caused by a slip-stick of the clutch plates in the transfer case clutch pack. On 1999 to 2002 models, the preload that is designed into the clutch pack may contribute to the condition. In addition, contamination of the fluid may interfere with the friction modifiers. Correction Flush and replace the transfer case fluid on affected vehicles using the following procedure and the part number listed below. Perform the following diagnosis prior to flushing and replacing the transfer case fluid in order to properly identify the shudder. Diagnosis 1. Verify the shudder in the vehicle. The vehicle needs to be at operating temperature (driven at least 8 km (5 mi) for proper diagnosis. After the vehicle is at operating temperature, drive in a tight circle just short of steering wheel lock, at a speed less than 8 km/h (5 mph) in order to identify the shudder. 2. Identify what rear axle type the vehicle has. ^ If the vehicle has a standard rear axle, then proceed to step 3. ^ If the vehicle has a locking rear axle, remove the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. Drive the vehicle as outlined in step 1. ^ If the shudder goes away, install the front propeller shaft and proceed to step 3. Refer to the Propeller Shaft subsection in the Service Manual. ^ If the shudder does not go away, the locking rear axle may be the cause. Evaluate the condition using diagnostic information in the appropriate Service Manual. ^ Install the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. 3. Flush the transfer case with the blue colored fluid (AUTO-TRAK II) using the procedure and part number listed below. Perform the flush procedure even if the transfer case contains the blue colored AUTO-TRAK II fluid in order to remove any possible contaminants. The AUTO-TRAK II fluid contains an improved friction modifier that should correct the slip-stick condition. Refer to the Transfer Case subsection in the Service Manual for information on draining and filling the transfer case. Flush Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns > Page 1362 Important: Refer to Corporate Bulletin Number 99-04-21-001 dated April 1999, for important information on removing the transfer case drain and fill plugs. 1. Drain the transfer case fluid. 2. Refill the transfer case with 2L (2 qts) of new fluid, P/N 12378508 (Canadian P/N 10953626). 3. After refilling the transfer case, drive the vehicle a minimum of 8 km (5 mi). 4. With the transfer case at operating temperature, drain the transfer case fluid again. 5. Refill the transfer case with new fluid. Important: The vehicle may require approximately 160 km (100 miles) of driving before the condition is completely corrected. 6. If this procedure does not correct the shudder condition, please call the Technical Assistance Center for further instructions and review PIP3012D or newer. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Transfer Case Shudder On Tight Turns Bulletin No.: 99-04-21-005E Date: November 28, 2005 TECHNICAL Subject: Transfer Case Shudder (Flush and Replace Transfer Case Fluid) Models: 1999-2005 Chevrolet Astro (AWD) 1999-2005 GMC Safari (AWD) 1999-2001 Oldsmobile Bravada with All-Wheel Drive (NV 136) Transfer Case (RPO NP4) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 99-04-21-005D (Section 04 - Driveline/Axle). Condition Some customers may comment on a vibration (shudder) during tight turning maneuvers on dry pavement at vehicle speeds less than 8 km/h (5 mph). Cause This condition may be caused by a slip-stick of the clutch plates in the transfer case clutch pack. On 1999 to 2002 models, the preload that is designed into the clutch pack may contribute to the condition. In addition, contamination of the fluid may interfere with the friction modifiers. Correction Flush and replace the transfer case fluid on affected vehicles using the following procedure and the part number listed below. Perform the following diagnosis prior to flushing and replacing the transfer case fluid in order to properly identify the shudder. Diagnosis 1. Verify the shudder in the vehicle. The vehicle needs to be at operating temperature (driven at least 8 km (5 mi) for proper diagnosis. After the vehicle is at operating temperature, drive in a tight circle just short of steering wheel lock, at a speed less than 8 km/h (5 mph) in order to identify the shudder. 2. Identify what rear axle type the vehicle has. ^ If the vehicle has a standard rear axle, then proceed to step 3. ^ If the vehicle has a locking rear axle, remove the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. Drive the vehicle as outlined in step 1. ^ If the shudder goes away, install the front propeller shaft and proceed to step 3. Refer to the Propeller Shaft subsection in the Service Manual. ^ If the shudder does not go away, the locking rear axle may be the cause. Evaluate the condition using diagnostic information in the appropriate Service Manual. ^ Install the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. 3. Flush the transfer case with the blue colored fluid (AUTO-TRAK II) using the procedure and part number listed below. Perform the flush procedure even if the transfer case contains the blue colored AUTO-TRAK II fluid in order to remove any possible contaminants. The AUTO-TRAK II fluid contains an improved friction modifier that should correct the slip-stick condition. Refer to the Transfer Case subsection in the Service Manual for information on draining and filling the transfer case. Flush Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns > Page 1368 Important: Refer to Corporate Bulletin Number 99-04-21-001 dated April 1999, for important information on removing the transfer case drain and fill plugs. 1. Drain the transfer case fluid. 2. Refill the transfer case with 2L (2 qts) of new fluid, P/N 12378508 (Canadian P/N 10953626). 3. After refilling the transfer case, drive the vehicle a minimum of 8 km (5 mi). 4. With the transfer case at operating temperature, drain the transfer case fluid again. 5. Refill the transfer case with new fluid. Important: The vehicle may require approximately 160 km (100 miles) of driving before the condition is completely corrected. 6. If this procedure does not correct the shudder condition, please call the Technical Assistance Center for further instructions and review PIP3012D or newer. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1374 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1375 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1376 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1382 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1383 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1384 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case ...................................................................................................................................... .............................................................. 1.9L (2.0 Qt) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1387 Fluid - Transfer Case: Fluid Type Specifications Transfer Case ............................................................................................................................................................. AutoTrak II Fluid GM P/N 12378508 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1392 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1393 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1396 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ......................................................................................................................................... 5W-30 (preferred) Above -18° C (0° F) ........................................................................................................... ........................................................ 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1397 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil in a suitable container. 3. Remove the engine oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the engine oil filter gasket with clean engine oil. 2. Install the engine oil filter. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1398 3. Follow the tightening instructions on the oil filter. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the drain plug to the oil pan. ^ Tighten the oil pan plug to 25 Nm (18 ft. lbs.). 5. Remove the safety stands and lower the vehicle. 6. Fill the engine with the proper capacity and quality of engine oil. 7. Operate the engine, check for leaks and oil pressure. 8. Check the oil level and add as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Fluid Type .......................... GM Power Steering Fluid GM P/N 1052884 - 1 pint (Canadian P/N 993294), 1050017 - 1 quart, (Canadian P/N 992646) or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1406 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1407 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 2.0 lb. (0.91 kg.) Air Conditioning Refrigerant with Rear A/C .............................................................................................................................................. 3.0 lb. (1.36 kg.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1410 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant R134a Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1411 Refrigerant: Service Precautions CAUTION: - Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1412 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly,accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1419 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil (R-134a system) PAG oil Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1420 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fluids > Washer Fluid > Component Information > Diagrams Rear Window Washer Fluid Pump Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications BRAKE FLUID Delco Supreme II .............................................................................................................................................. GM P/N 12377967 (Canadian P/N 992667) - or equivalent DOT-3 brake fluid CAUTION: The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 15. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1429 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Hydraulic Brake System Bleeding-Manual Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II09 GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder; then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 7. Have an assistant slowly depress the brake pedal fully and maintain pedal position. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit; install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 12. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit; install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit; install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 14. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 15. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 17. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1430 17.1. Inspect the brake system for external leaks. 17.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 18. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 19. If the brake system warning lamp remains illuminated, the hydraulic brake pressure differential switch plunger may have be forced out of position during the bleeding procedure and may need to be reset. Perform the following steps to reset the switch. 19.1. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 19.2. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II - GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 19.3. With the ignition key still ON, with the engine OFF, loosen the bleeder valve. 19.4. Have an assistant slowly depress the brake pedal until the brake system warning lamp turns OFF and maintain pedal position while you tighten the bleeder valve. 19.5. Have the assistant slowly release the brake pedal. 20. If the brake system warning lamp continues to remain illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Hydraulic Brake System Bleeding-Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required - J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 29567 Brake Pressure Bleeder Adapter - J 39177Combination Valve Pressure Bleeding Tool, or equivalent - J 41618 Brake Bleeder Adapter Set Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Remove the cap from the metering valve end of the combination valve, then install the J39177, or equivalent to the metering valve. 6. Using the J39177, depress the shaft of the metering valve to maintain the proper flow of brake fluid to the front wheel hydraulic circuit during the pressure bleeding procedure. 7. Assemble the J 41613 to the J 29567. 8. Install the J 41618 and J 29567 to the brake master cylinder reservoir. 9. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1431 clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the J 29532, or equivalent, to the J 29567. 11. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 12. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 15. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 17. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 18. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right front hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 20. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 21. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 29567. 22. Remove the J 41618 and J 29567 from the brake master cylinder reservoir. 23. Remove the J39177, or equivalent from the metering valve, then install the cap to the metering valve end of the combination valve. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1432 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1437 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor connector (1) located on the frame crossmember. 7. Disconnect the inflatable restraint front end discriminating sensor connector. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1438 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1439 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 7. Disconnect the I/P module yellow 2-way connector (1). Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1440 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1441 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connector to the inflatable restraint front end discriminating sensor (1) located on the frame crossmember. 2. Install the CPA to the inflatable restraint front end discriminating sensor connector. 3. Install the AIR BAG fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1442 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6 Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1443 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the passenger knee bolster. 5. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1444 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the passenger knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Convenience Center > Page 1452 Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Convenience Center > Page 1453 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) Fuse: Application and ID Fuse Block I/P (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1456 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1457 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1458 Fuse: Application and ID Fuse Block I/P (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1459 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1460 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1461 Fuse: Application and ID Fuse Block - Underhood (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1462 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1463 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1464 Fuse: Application and ID Fuse Block - Underhood (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1465 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1466 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1467 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1468 Fuse: Application and ID Fuse Block I/P (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1469 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1470 Application Table Part 2 Fuse Block I/P (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1471 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1472 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1473 Application Table Part 3 Fuse Block - Underhood (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1474 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1475 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1476 Application Table Part 2 Fuse Block - Underhood (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1477 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1478 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1479 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1480 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1481 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1482 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1483 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1484 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1489 Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1490 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Convenience Center C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1493 Convenience Center C3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1494 Convenience Center C4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1495 Convenience Center C5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1496 Convenience Center C6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1497 Convenience Center C8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1498 Convenience Center C9 (Upfitter) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1499 Convenience Center C10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1502 Fuse Block: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1503 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1504 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1505 Fuse Block: Application and ID Fuse Block - Underhood (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1506 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1507 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1508 Fuse Block: Application and ID Fuse Block - Underhood (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1509 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1510 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1511 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1512 Fuse Block: Application and ID Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1513 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1514 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1515 Application Table Part 3 Fuse Block - Underhood (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1516 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1517 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1518 Application Table Part 2 Fuse Block - Underhood (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1519 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1520 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1521 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1522 Application Table Part 4 Fuse Block I/P (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1523 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1524 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1525 Application Table Part 2 Fuse Block I/P (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1526 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1527 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 1528 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Convenience Center > Page 1533 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Convenience Center > Page 1534 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Convenience Center > Page 1535 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1538 Relay Box: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1539 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1540 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1541 Relay Box: Application and ID Relay Block #1 And #2 Relay Block No.1 Part 1 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1542 Relay Block No.1 Part 2 Relay Block No.2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1543 Application Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1544 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1545 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1546 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1547 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1548 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 1549 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the symbols shown when commanded ON. The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 1561 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 1562 Vehicle Lifting Points The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 1563 The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Spare Tire Carrier Mounting Bolts 11 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 1587 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Removal Procedure 1. Remove the spare tire from the tire carrier. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the pin and retainer from the shaft. 4. Remove the shaft from the hoist. 5. Remove the hoist mounting bolts. 6. Remove the hoist from the rear crossmember. Installation Procedure 1. Install the hoist to the rear crossmember. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hoist mounting bolts and nuts. ^ Tighten the hoist mounting bolts and nuts to 15 Nm (11 ft. lbs.). 3. Install the shaft to the hoist. 4. Install the pin and retainer to the shaft. 5. Lower the vehicle. 6. Install the spare tire to the carrier. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1596 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1597 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1598 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1603 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1608 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1609 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1610 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1616 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1617 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1618 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1623 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1628 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1629 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1634 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1635 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1636 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1641 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1646 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1647 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1648 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1658 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1659 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1660 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1665 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1670 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1671 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1676 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 200 - 229 mm (09 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1677 ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 1680 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrape ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1684 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 5 Wheel Bearings Diagnosis Step 6 - 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1685 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1686 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 1692 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 1693 Axle Nut: Specifications Axle Shaft Nut 147 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1702 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1708 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 04-03-10-004 > May > 04 > Wheels - Wheel Fastener Torque Specification Update Wheel Fastener: All Technical Service Bulletins Wheels - Wheel Fastener Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 04-03-10-004 Date: May, 2004 SERVICE MANUAL UPDATE Subject: Revised Tire and Wheel Removal and Installation Fastener Tightening Specification Models: 2003 Chevrolet Astro Van 2003 GMC Safari Van This bulletin is being issued to revise the fastener tightening specification in the Tire and Wheel Removal and Installation procedure in the Tires and Wheels sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct tightening specification for the wheel nuts (Step 2 of Installation) is 190 N.m (140 lb ft). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 02-03-10-008 > Dec > 02 > Wheels/Tires Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 04-03-10-004 > May > 04 > Wheels - Wheel Fastener Torque Specification Update Wheel Fastener: All Technical Service Bulletins Wheels - Wheel Fastener Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 04-03-10-004 Date: May, 2004 SERVICE MANUAL UPDATE Subject: Revised Tire and Wheel Removal and Installation Fastener Tightening Specification Models: 2003 Chevrolet Astro Van 2003 GMC Safari Van This bulletin is being issued to revise the fastener tightening specification in the Tire and Wheel Removal and Installation procedure in the Tires and Wheels sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct tightening specification for the wheel nuts (Step 2 of Installation) is 190 N.m (140 lb ft). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 02-03-10-008 > Dec > 02 > Wheels/Tires Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1726 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1727 Wheel Nut Torque Sequence Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the rotor. Important: Do not hammer on a wheel stud. 4. Remove the wheel stud using J 43631. Installation Procedure 1. Install the wheel stud to the wheel hub and bearing assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install 4 washers and the nut to the wheel stud. ^ Tighten the wheel stud nut to 130 Nm (95 ft. lbs.), drawing in the wheel stud. 3. Remove the nut and the washers from the wheel stud. 4. Install the rotor. 5. Install the tire and the wheel. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1730 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement (Rear Drum Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the brake drum. 4. Remove the wheel stud from the axle flange using J 43631. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1731 1. Start the new stud into the axle flange hole by pressing firmly with your hand. 2. Install a washer and thread the lug nut on the wheel stud with the flat side of the lug nut to the vehicle. 3. Tighten the lug nut in order to draw the wheel stud into the rear of the flange. 4. Remove the lug nut and washers from the wheel stud. 5. Install the brake drum. 6. Install the tire and the wheel. 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 1732 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1736 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1737 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair Towing Information: Service and Repair TOWING A TRAILER Caution: The driver can lose control when pulling a trailer if the correct equipment is not used or the vehicle is not driven properly. For example, if the trailer is too heavy, the brakes may not work well or even at all. The driver and passengers could be seriously injured. The vehicle may also be damaged; the resulting repairs would not be covered by the vehicle warranty. WEIGHT OF THE TRAILER Two-Wheel Drive Cargo (3.42 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5300 lbs (2406 kg) GCWR ........................ .............................................................................................................................................................. ................ 9500 lbs (4313 kg) Cargo (3.73 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5800 lbs (2633 kg) GCWR ........................ .............................................................................................................................................................. .............. 10000 lbs (4540 kg) Passenger (3.42 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 4900 lbs (2225 kg) GCWR ................ .............................................................................................................................................................. ........................ 9500 lbs (4313 kg) Passenger (3.73 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 5400 lbs (2452 kg) GCWR ................ .............................................................................................................................................................. ...................... 10000 lbs (4540 kg) All-Wheel Drive Cargo (3.42 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5100 lbs (2315 kg) GCWR ........................ .............................................................................................................................................................. ................ 9500 lbs (4313 kg) Cargo (3.73 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5600 lbs (2542 kg) GCWR ........................ .............................................................................................................................................................. .............. 10000 lbs (4540 kg) Passenger (3.42 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 4600 lbs (4088 kg) GCWR ................ .............................................................................................................................................................. ........................ 9500 lbs (4313 kg) Passenger (3.73 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 5100 lbs (2315 kg) GCWR ................ .............................................................................................................................................................. ...................... 10000 lbs (4540 kg) NOTE: Maximum trailer weight is calculated assuming the driver and one passenger are in the tow vehicle and it has all the required trailering equipment. The weight of additional optional equipment, passengers and cargo in the tow vehicle must be subtracted from the maximum trailer weight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 1744 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 1745 Vehicle Lifting Points The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 1746 The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures Access Cover: Procedures Engine Cover ENGINE COVER Removal Procedure 1. Remove the instrument panel extension. Refer to "Instrument Panel Extension". 2. Remove the floor air outlet duct. Refer to "Air Outlet - Center Floor". 3. Remove the bolts from the brackets: ^ Loosen the bolt. ^ Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1753 6. Remove the engine cover. Installation Procedure 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. 3. Install the latch screws. Tighten Tighten the latch screws to 4 Nm (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten Tighten the engine cove bolt to 25 Nm (18 lb ft). 5. Insert the floor air outlet duct. 6. Insert the instrument panel extension. Instrument Panel (IP) Extension INSTRUMENT PANEL (I/P) EXTENSION REPLACEMENT REMOVAL PROCEDURE 1. Remove the caps that cover the extension screws. 2. Remove the screws from the extension. 3. Remove the nuts at the bottom of the extension. 4. Pull toward the rear of the vehicle in order to remove the extension from the instrument panel. 5. Disconnect the electrical connectors. INSTALLATION PROCEDURE 1. Connect the electrical connectors. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1754 2. Install the extension to the instrument panel: 2.1. Align the retainers. 2.2. Press the extension into place until the retainers are seated. 3. Install the nuts that retain the extension to the floor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts that retain the extension to the floor to 8 Nm (71 lb in). 4. Install the retaining screws. Tighten Tighten the screws to 8 Nm (71 lb in). 5. Install the extension screw covers. Air Outlet - Center Floor AIR OUTLET REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE 1. Remove the IP extension. Refer to "Instrument Panel (I/P) Extension". 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. Refer to "Seat Replacement Bucket". 4. Remove the front section of the carpet, if equipped. Refer to "MAT/Carpet Replacement". Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1755 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE 1. Install the floor air outlet to the ducts to the rear seat, if equipped. 2. Install the retaining nuts to the floor outlet duct, if equipped. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1756 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 Nm (18 lb in). 3. Install the front section of the carpet, if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct from the air distributor. 6. Install the IP extension. Engine Cover Guide Assembly ENGINE COVER GUIDE ASSEMBLY Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement. 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly from the vehicle. Installation Procedure 1. Install the engine cover guide assembly. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten Tighten the bolts that retain the engine cover guide to 8.5 Nm (75 lb in). 3. Install the engine cover. MAT/Carpet Replacement MAT/CARPET REPLACEMENT - FRONT FLOOR REMOVAL PROCEDURE 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket. 2. Remove the engine cover, if required. Refer to Engine Cover Replacement. 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement. 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1757 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 9. Remove the carpet/mat from the vehicle. INSTALLATION PROCEDURE CAUTION: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. NOTICE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. TIGHTEN Screws to 2 Nm (18 lb. in.). 4. Install the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement. 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. 7. Install the engine cover, if required. Refer to Engine Cover Replacement. 8. Install the seats and the risers. Refer to Seat Replacement - Bucket in Seats. Seat Replacement - Bucket SEAT REPLACEMENT - BUCKET REMOVAL PROCEDURE 1. Remove the seat belt from the side of the seat belt guide. 2. Remove the nuts that retain the seat to the floor. 3. Disconnect the electrical connector from the power seat if equipped. 4. Remove the seat and the riser from the vehicle. 5. Remove the seat belt guide from the seat riser. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1758 6. Remove the bolts that retain the seat to the riser. 7. Remove the power seat from the seat risers if equipped. 8. Remove the manual seat adjuster wire from the seat tracks. 9. Remove the seat riser spacer nuts and bolts from the seat tracks. 10. Remove the seat riser spacer from the seat risers. INSTALLATION PROCEDURE 1. Install the seat riser spacer to the seat risers. 2. Install the seat riser spacer nuts and bolts to the seat tracks. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat riser spacer nuts and bolts to the seat tracks to 30 Nm (22 lb ft). 3. Install the manual seat adjuster wire to the seat tracks. 4. Install the power seat to the seat risers if equipped. 5. Install the seat belt guide to the seat riser. 6. Install the nuts that retain the seat to the risers. Tighten Tighten the nuts that retain the seat to the riser to 43 Nm (32 lb ft). 7. Install the seat and the seat riser in the vehicle. 8. Connect the electrical connector to the power seat if equipped. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1759 9. Install the nuts that retain the seat to the floor. Tighten Tighten the nuts that retain the seat to the floor to 43 Nm (32 lb ft). 10. Install the seat belt to the side of the seat belt guide. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1760 Access Cover: Removal and Replacement Engine Cover Replacement Engine Cover Replacement Removal Procedure 1. Remove the instrument panel extension. Refer to Instrument Panel (I/P) Extension Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel, Gages, and Console/Instrument Panel (I/P) Extension Replacement) in Instrument Panel, Gages and Console. 2. Remove the floor air outlet duct. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. 3. Remove the bolts from the brackets: 1. Loosen the bolt. 2. Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. 6. Remove the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1761 Installation Procedure 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the latch screws. Tighten the latch screws to 4 N.m (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten the engine cover bolt to 25 N.m (18 lb ft). 5. Insert the floor air outlet duct. Refer to Instrument Panel (I/P) Extension Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel, Gages, and Console/Instrument Panel (I/P) Extension Replacement) in Instrument Panel, Gages and Console. 6. Insert the instrument panel extension. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. Engine Cover Guide Replacement Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1762 Engine Cover Guide Replacement Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly. Installation Procedure 1. Install the engine cover guide assembly. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten the bolts that retain the engine cover guide to 8.5 N.m (75 lb in). 3. Install the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1766 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml. (1 oz.) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Remove the engine cover. 2. Remove the air cleaner assembly. 3. Remove the radiator. 4. Remove the A/C condenser. 5. Remove the radiator grille. 6. Remove the valve lifters. 7. Remove the timing chain and the camshaft sprocket. 8. Remove the balance shaft drive gear. 9. Remove the camshaft. 10. Clean and inspect the camshaft and the bearings. Installation Procedure Important: Whenever a new camshaft is installed, do the following procedures: ^ Change the engine oil. ^ Change the engine oil filter. ^ Add GM Engine Oil Supplement GM P/N 1052367 (Canadian P/N 992869) or the equivalent to the engine oil. 1. Install the camshaft into the engine block. 2. Install the balance shaft drive gear. 3. Install the timing chain and camshaft sprocket. 4. Install the valve lifters. 5. Install the A/C condenser. 6. Install the radiator grille. 7. Install the radiator. 8. Fill the engine cooling system. 9. Recharge the air conditioning system. 10. Install the air cleaner assembly. 11. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Removal Procedure 1. Remove the lower intake manifold. 2. Remove the valve rocker arms and the valve push rods. 3. Remove the valve lifters. 4. Use a cleaning solvent and a shop towel to clean any varnish from the valve lifter bores. 5. Inspect the valve lifter bores for excessive wear or scoring. Replace the engine block if there is excessive wear or deep scoring. 6. Inspect the camshaft for wear or damage. If the wear is questionable remove the camshaft and inspect. 7. Clean and inspect the valve lifters and the valve pushrod guide. Installation Procedure Important: It is normal for NEW lifters to make a slight ticking noise when the engine is first started. Increasing the engine RPMs slightly to raise oil pressure should stop the noise. 1. Install the valve lifters. 2. Install the valve rocker arms and push rods. 3. Install the lower intake manifold. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Right ^ Refer to Valve Rocker Arm Cover Replacement - Left 2. Remove the valve rocker arm and the valve pushrod. 3. Clean and inspect the valve rocker arm and the valve pushrod. Installation Procedure 1. Install the valve rocker arm and the valve pushrod. 2. Install the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Left ^ Refer to Valve Rocker Arm Cover Replacement - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Right ^ Refer to Valve Rocker Arm Cover Replacement - Left 2. Remove the valve rocker arm and the valve pushrod. 3. Clean and inspect the valve rocker arm and the valve pushrod. Installation Procedure 1. Install the valve rocker arm and the valve pushrod. 2. Install the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Left ^ Refer to Valve Rocker Arm Cover Replacement - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Engine - Balance Shaft Rattling Noises (Cancellation) Balance Shaft: Technical Service Bulletins Engine - Balance Shaft Rattling Noises (Cancellation) Bulletin No.: 00-06-01-023C Date: August 30, 2006 TECHNICAL Subject: Engine/Balance Shaft "Rattle" Noise Models: 1992-2003 Chevrolet and GMC C/K, S/T, M/L, G and P Models 1992-2001 Oldsmobile Bravada with 4.3 L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to cancel this bulletin. Please discard Corporate Bulletin Number 00-06-01-023B (Section 06 -- Engine/Propulsion System). Technicians should refer to Corporate Bulletin Number 03-06-01-024C for information on engine/balance shaft "rattle" noise concerns. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Page 1785 Balance Shaft: Service and Repair Balance Shaft Replacement Removal Procedure 1. Remove the radiator. 2. Remove the A/C condenser, if equipped. 3. Remove the valve lifter pushrod guide. 4. Remove the camshaft timing chain and sprockets. Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 5. Remove the balance shaft. 6. Clean and inspect the balance shaft. Installation Procedure 1. Install shaft. 2. Install the camshaft timing chain and the camshaft sprocket. 3. Install the crankshaft position reluctor ring and the engine front cover. 4. Install the valve lifter pushrod guide. 5. Install the A/C condenser, if equipped. 6. Install the radiator. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance-Production .................................................................................................... 0.038 - 0.078 mm (0.0015 - 0.0031 inch) Connecting Rod Bearing Clearance-Service ......................................................................................................... 0.025 - 0.063 mm (0.0010 0.0025 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Nut First Pass ............................................................................................................................................. .................................................. 27 Nm (20 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 70 degrees Connecting Rod Side Clearance .................................................................................................................................... 0.15 - 0.44 mm (0.006 - 0.017 inch) Connecting Rod Journal Diameter .................................................................................................................... 57.116 - 57.148 mm (2.2487 - 2.2497 inch) Connecting Rod Journal Out-of-Round - Production ....................................................................................................................... 0.005 mm (0.0002 inch) Connecting Rod Journal Out-of-Round-Service .............................................................................................................................. 0.025 mm (0.0010 inch) Connecting Rod Journal Taper-Production ............................................................................................................................... 0.00508 mm (0.00030 inch) Connecting Rod Journal Taper-Service ........................................................................................................................................... 0.025 mm (0.0010 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Tighten the crankshaft bearing cap bolts. Tighten the crankshaft bearing cap bolts on the first pass to 20 Nm (15 ft. lbs.). Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660-A Crankshaft Bearing Cap Bolt- Preferred Method First Pass ............................................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 73 degrees Crankshaft Bearing Cap Bolt - Optional Strategy ................................................................................................................................... 105 Nm (77 ft. lbs.) Crankshaft Main Bearing Bore Out-of-Round ................................................................................................................................... 0 050 mm (0.002 inch) Crankshaft Main Bearing Clearance #1 - Production ................................................................................................ 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Crankshaft Main Bearing Clearance #2, #3, and #4-Production ........................................................................... 0.028 - 0.058 mm (0.0011 - 0.0023 inch) Crankshaft Main Bearing Clearance #1-Service ................................................................................................... 0.0254 - 0.05 mm (0.0010 - 0.0020 inch) Crankshaft Main Bearing Clearance #2, #3, and #4-Service ................................................................................. 0.025 - 0.063 mm (0.0010 - 0.0025 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Housing Replacement Removal Procedure Important: Do not remove the crankshaft rear oil seal housing if only replacing the crankshaft rear oil seal. 1. Remove the oil pan. 2. Remove the transmission assembly. 3. Remove the engine flywheel. 4. Remove the bolts and the nut holding the crankshaft rear oil seal housing to the engine. 5. Remove the crankshaft rear oil seal housing. 6. Remove and discard the crankshaft rear oil seal housing gasket. 7. Clean all the sealing surfaces. 8. Inspect and replace the crankshaft rear oil seal housing for warping, cracks, wear, or damage. Installation Procedure Important: When installing a NEW crankshaft rear oil seal housing the crankshaft rear oil seal will come with the housing. If reusing the housing and then installing a NEW seal follow the instructions for installing the housing and than refer to Crankshaft Rear Oil Seal Replacement to install the seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 1798 1. Install a NEW crankshaft rear oil seal housing gasket. 2. Install the NEW crankshaft rear oil seal housing with the oil seal to the engine block using the following procedure. Important: Do not oil or grease the seal lip or the crankshaft seal area. 2.1. Leave the sleeve in the crankshaft rear oil seal and use the sleeve as a guide to ease the seal lip over the end of the crankshaft. 2.2. Push the crankshaft rear oil seal housing fully onto the crankshaft until the crankshaft rear oil seal housing is against the crankshaft rear oil seal gasket and the engine. 2.3. Remove the sleeve. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nut to the crankshaft rear oil seal housing. ^ Tighten the crankshaft rear oil seal housing bolts and nut to 12 Nm (106 inch lbs.). 4. Install the engine flywheel. Notice: Any time the transmission and the engine oil pan are off of the engine at the same time, install the transmission before the oil pan. This is to allow for the proper oil pan alignment. Failure to achieve the correct oil pan alignment can result in transmission failure. 5. Install the transmission assembly. 6. Install the oil pan. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft End Play .................................................................................................................................................... 0.050 - 0.20 mm (0.002 - 0.008 inch) Crankshaft Main Journal Diameter #1 .............................................................................................................. 62.199 - 62.217 mm (2.4488 - 2.4495 inch) Crankshaft Main Journal Diameter #2 and #3 .................................................................................................. 62.191 - 62.215 mm (2.4485 2.4494 inch) Crankshaft Main Journal Diameter #4 .............................................................................................................. 62.179 - 62.203 mm (2.4480 - 2.4489 inch) Crankshaft Main Journal Out-of-Round-Production ........................................................................................................................ 0.005 mm (0.0002 inch) Crankshaft Main Journal Out-of-Round-Service ............................................................................................................................. 0.025 mm (0.0010 inch) Crankshaft Main Journal Taper ....................................................................................................................................................... 0.007 mm (0.0003 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Coolant Heater Replacement Removal Procedure 1. Drain the engine coolant. 2. If not originally equipped with an engine coolant heater, remove the coolant jacket plug by using the following procedure: 2.1. Carefully tap the coolant jacket plug near the outer edge. This causes the plug to rotate in the hole. Do not score the machined surface of the hole. 2.2. Grasp the plug with pliers and pull the plug out. 3. Remove the cord from the engine coolant heater. 4. Loosen the bolt. 5. Remove the engine coolant heater. 6. Clean the core plug hole. Remove any of the following conditions: ^ Burrs ^ Compound ^ Paint ^ Rough spots Installation Procedure 1. Apply a coating of lubricant to the O-ring seal and the cleaned surface of the plug opening in the block. Use a water spray resistant Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 1805 high-temperature grease lubricant (GM P/N 9985164 or equivalent). Notice: The block heater element must not touch the engine block inner wall in the installed position or damage to the engine block and the block heater could result. 2. Install the engine block heater into the engine block. Position the heater element 90 degrees perpendicular (1) to the crankshaft centerline. 3. Push the engine coolant heater into the block until the outer edge is flush with the engine block surface. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the bolt until both locking wings draw tight against the inner wall of the engine block. ^ Tighten the bolt to 1.9 Nm (17 inch lbs.). Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 1806 5. Install the heater cord to the coolant heater. Route and secure the heater cord through the engine as shown. 6. Route and secure the heater cord across the engine cowl as shown. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 1807 7. Route and secure the heater cord to the VCM wiring harness. 8. Fill the reservoir with engine coolant. 9. Inspect the system for leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt ......................................................................................................................... ..................................................... 58 Nm (43 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1811 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Removal Procedure 1. Remove the fan shroud assembly. ^ Refer to Fan Shroud Replacement - Upper ^ Refer to Fan Shroud Replacement - Lower 2. Remove the drive belt. 3. Remove the crankshaft balancer. 4. Clean and inspect all parts. Installation Procedure 1. Apply a small amount of grease to the crankshaft front cover oil seal sealing surface if reusing the seal. 2. Install the crankshaft balancer. 3. Install the drive belt. 4. Install the fan shroud assembly. ^ Refer to Fan Shroud Replacement - Upper ^ Refer to Fan Shroud Replacement - Lower Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston-Piston to Bore Clearance-Production ......................................................................................................... 0.018 - 0.061 mm (0.0007 0.0024 inch) Piston-Piston to Bore Clearance-Service ......................................................................................................................................... 0.075 mm (0.0029 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring End Gap-First Compression Ring-Production ........................................................................................... 0.25 - 0.40 mm (0.010 - 0.016 inch) Piston Ring End Gap-Second Compression Ring-Production ....................................................................................... 0.38 - 0.58 mm (0.015 - 0.023 inch) Piston Ring End Gap-Oil Control Ring-Production ...................................................................................................... 0.25 - 0.76 mm (0.010 - 0.029 inch) Piston Ring End Gap-First Compression Ring-Service ................................................................................................. 0.25 - 0.50 mm (0.010 - 0.020 inch) Piston Ring End Gap-Second Compression Ring-Service ............................................................................................ 0.38 - 0.80 mm (0.015 - 0.031 inch) Piston Ring End Gap-Oil Control Ring-Service .................................................................................................... 0.005 - 0.090 mm (0.0002 - 0.0035 inch) Piston Ring to Groove Clearance-First Compression Ring-Production ................................................................ 0.030 - 0.070 mm (0.0012 - 0.0027 inch) Piston Ring to Groove Clearance-Second Compression Ring Production ............................................................ 0.076 - 0.280 mm (0.0030 - 0.0110 inch) Piston Ring to Groove Clearance-Oil Control Ring Production ............................................................................ 0.046 - 0.196 mm (0.0018 - 0.0077 inch) Piston Ring to Groove Clearance-First Compression Ring-Service ...................................................................... 0.030 - 0.085 mm (0.0012 - 0.0033 inch) Piston Ring to Groove Clearance-Second Compression Ring-Service .................................................................. 0.030 - 0.085 mm (0.0012 - 0.0033 inch) Piston Ring to Groove Clearance-Oil Control Ring-Service ................................................................................. 0.076 - 0.200 mm (0.0030 - 0.0079 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1826 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1827 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Right ^ Refer to Valve Rocker Arm Cover Replacement - Left 2. Remove the valve rocker arm and the valve pushrod. 3. Clean and inspect the valve rocker arm and the valve pushrod. Installation Procedure 1. Install the valve rocker arm and the valve pushrod. 2. Install the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Left ^ Refer to Valve Rocker Arm Cover Replacement - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Rocker Arm Cover Bolts ...................................................................................................................... .................................................... 12 Nm (106 lb in) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left) Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Remove the engine cover. 2. Remove the oil filler tube and bolt. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover. 5. Remove the rear spark plug wire retainer from the support. 6. Remove the valve rocker arm cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 1836 7. Clean all sealing surfaces and the valve rocker arm cover. Installation Procedure 1. Install the valve rocker arm cover and bolts. Tighten Tighten bolts to 12 Nm (106 lb in). 2. Install the PCV valve hose assembly to the intake manifold and in the valve rocker arm cover. 3. Install the rear spark plug wire retainer to the support. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the oil filler tube and bolt. Tighten Tighten the bolt to 25 Nm (18 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 1837 5. Connect the ECT sensor electrical connector. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 1838 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right) Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. Remove the engine cover. 2. Disconnect the spark plug wires for the right side of the engine from the distributor cap. 3. Remove the PCV tube from the valve rocker arm cover and the air cleaner outlet duct. 4. Remove the engine wiring harness bracket from the EVAP canister purge solenoid valve stud. 5. Move the engine wiring harness aside. 6. Remove the right valve rocker arm cover. 7. Clean all sealing surfaces and the valve rocker arm cover. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 1839 1. Install the right valve rocker arm cover and bolts. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine wiring harness bracket and nut to EVAP canister purge solenoid valve stud. Tighten Tighten the engine wiring harness bracket nut to 8 Nm (71 lb in). 3. Install the PCV hose in the valve rocker arm cover bolts and the air cleaner outlet duct. Tighten Tighten bolts to 12 Nm (106 lb in). 4. Connect the spark plug wires to the distributor cap. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 5892-D Valve Spring Compressor Removal Procedure 1. Remove the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Left ^ Refer to Valve Rocker Arm Cover Replacement - Right 2. Remove the required valve rocker arms. 3. Remove the required spark plugs. 4. Install the J 22794 into the spark plug hole. 5. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 6. Remove a bolt from a valve rocker arm. 7. Install a flat washer on the bolt. 8. Install the bolt in the valve rocker arm bolt hole for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 9. Use the J 5892-D in order to compress the valve spring. 9.1. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9.2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1843 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use J 38606 when J 5892-D will not fit. 11. Remove the valve keys (1). 12. Carefully release the valve spring tension. 13. Remove the J 5892-D or J 38606. 14. Remove the valve spring cap (2) and valve spring (3). 15. Remove the valve stem oil seal (4). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1844 1. Install the valve seals (4). 2. Install the valve spring (3). 3. Install the valve spring cap (2) on the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 4. To press the valve spring (3) use the J 5892-D Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 5. Use the J 38606 if the clearance does not permit use of the J 5892-D 6. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 7. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 8. Remove the J 5892-D or the J 38606. 8.1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 8.2. Tap the end of the valve stem with a plastic faced hammer in to seat the valve stem keys, if necessary. 9. Remove the J 22794 10. Install the spark plugs. 11. Install the valve rocker arms to the cylinder head. 12. Install the valve rocker arm cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1850 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1851 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1852 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > With Air Conditioning With A/C Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > With Air Conditioning > Page 1855 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1856 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Steps 1-15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of rubber dust. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1859 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation procedure. 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1860 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Steps 1-6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1861 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Steps 1-12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1862 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Steps 1-8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1863 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Steps 1-15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1864 rubber dust. 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation procedure. 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Steps 1-6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1865 Steps 1-12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1866 Steps 1-8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1867 Steps 1-9 Diagnostic Aids A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent verify the accessory drive components by varying their loads. Ensure the accessory components are operated to their maximum capacity. An overcharged A/C system or power steering system with: a pinched hose, an incorrect fluid, or a failed generator are suggested items to inspect. Test Description The numbers refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt or an accessory drive component. If the drive belt is removed, the water pump may not operate. Without the water pump the engine may overheat. DTCs may set when the engine is operating with the drive belt removed. 4. This test verifies that an accessory drive component does not have a seized bearing. Remove the belt and test the bearings for smooth turning in the accessory drive components. Test the accessory drive components with the engine operating, vary the load on the components to verify that the components operate correctly. 5. This test is to verify that the drive belt tensioner operates correctly. If the drive belt tensioner is not operating correctly, correct belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working correctly. Also if an incorrect length drive belt was installed, it may not be routed correctly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a pulley that is incorrectly aligned using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1868 Steps 1-11 Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1869 Steps 1-5 Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. DTCs may set if the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the correct inspection and replacement procedure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1870 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the air cleaner outlet duct from the throttle body. 3. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 4. Remove the drive belt. 5. Slowly release the tension on the drive belt tensioner arm. Installation Procedure 1. Route the belt over all the pulleys except the tensioner arm. 2. Observe drive belt routing for vehicles without air conditioning. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1871 3. Observe drive belt routing for vehicles with air conditioning. 4. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 5. Install the drive belt over the drive belt tensioner pulley. 6. Slowly release the tension on the tensioner arm. 7. Inspect for the drive belt being properly installed on the pulleys. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1872 8. Avoid mis-positioning the drive belt by one or more grooves. 9. Confirm for the proper drive belt size and the correct drive belt routing by observing the location of the fix pointer and the index marks on the drive belt tensioner. With a new drive belt installed, the fix pointer should align within the indentation on the drive belt tensioner. 10. With a used drive belt installed, the fix pointer should not align past the index mark. 11. Install the air cleaner outlet duct. 12. Install the air cleaner assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the belt tensioner arm will move. Do not replace the belt tensioner because of movement in the belt tensioner arm. 1. Remove the drive belt. 2. Position a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise 3. Move the drive belt tensioner through it's full travel. ^ The movement should feel smooth. ^ There should be no binding. ^ The tensioner should return freely. 4. If any binding is observed, replace the drive belt tensioner. 5. Install the drive belt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1876 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the bolt. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the attaching bolt. ^ Tighten the tensioner assembly bolt to 50 Nm (37 ft. lbs.). 3. Install the drive belt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Inspect for loose or missing bolts at the following locations: ^ The engine mount bracket to the engine ^ The engine mount to the engine bracket through-bolts ^ The engine mount to frame bracket bolts 3. Replace loose or missing bolts. Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage. 4. In order to access the square tab on the left side of the engine remove the oil filter adapter. 5. In order to access the square tab on the right side of the engine remove the starter. 6. Using a jack on the square tab at the rear of the engine block (left side shown) raise the engine in order to complete the following tasks: ^ Remove weight from the engine mount. ^ Place a slight tension on the rubber cushion. ^ Observe the engine mount while raising the engine. 7. Replace the engine mount if the following conditions exist: ^ Heat check cracks cover the hard rubber surface. ^ The rubber cushion is separated from the metal plate of the engine mount. ^ There is a split through the rubber cushion. 8. Replace the starter, if removed. 9. Replace the oil filter adapter, if removed. 10. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement - Left Removal Procedure Notice: Refer to Engine Mounting Notice in Service Precautions. 1. Disconnect the battery negative cable. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil filter adapter. 4. Remove the engine mount through-bolt and nut for the side being replaced. Notice: Refer to Engine Lifting Notice in Service Precautions. 5. Using a jack on the square tab (left side shown) at the rear of the engine block, raise the engine only enough to remove the engine mount. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1882 6. Remove the bolts for the engine mount bracket to the engine. Access the upper two bolts for the right engine mount bracket through the fender wheelhouse. 7. Remove the engine mount bracket. 8. For AWD vehicle remove the bolts for the engine mount to the frame (left side shown). 9. Remove the engine mount. 10. For a RWD vehicle left side remove the bolts and the nuts for the engine mount to the frame bracket (left side shown). 11. If necessary, remove the left side engine mount frame bracket from the frame. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1883 1. For AWD vehicle install the engine mount to the frame (left side shown). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the AWD vehicle engine mount to the frame bolts. ^ Tighten the AWD vehicle engine mount to frame bolts to 59 Nm (44 ft. lbs.). 3. If removed, install the RWD vehicle left side bolts, nuts and engine mount frame bracket to the frame. ^ Tighten the engine mount frame bracket bolts to 47 Nm (35 ft. lbs.). ^ Tighten the engine mount frame bracket nuts to 42 Nm (31 ft. lbs.). 4. Install the RWD vehicle left side engine mount, the bolts, and the nuts to the frame bracket. ^ Tighten the engine mount to frame bolts to 47 Nm (35 ft. lbs.). ^ Tighten the engine mount to frame nuts to 42 Nm (31 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1884 5. Install the engine mount bracket to the engine. 6. Install the engine mount bracket bolts. ^ Tighten the engine mount bracket bolts to 64 Nm (47 ft. lbs.). 7. Lower the engine. 8. Install the engine mount through-bolt and the nut. ^ Tighten the engine mount through-bolt nuts to 68 Nm (50 ft. lbs.). 9. Install the oil filter adapter. 10. Lower the vehicle. 11. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1885 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Removal Procedure Notice: Refer to Engine Mounting Notice in Service Precautions. 1. Disconnect the battery negative cable. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the right front tire. 4. Remove the right fender wheelhouse extension. 5. Remove the starter. 6. Remove the engine mount through-bolt and nut. Notice: Refer to Engine Lifting Notice in Service Precautions. 7. Using a jack on the square tab (left side shown) at the rear of the engine block, raise the engine only enough to remove the engine mount. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1886 8. Remove the bolts for the engine mount bracket to the engine. Access the upper two bolts for the right engine mount bracket through the fender wheelhouse. 9. Remove the engine mount bracket. 10. For AWD vehicle remove the bolts for the engine mount to the frame (left side shown). 11. Remove the engine mount. 12. For a RWD vehicle right side remove the bolts and the nuts for the engine mount to the frame. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1887 1. Install the AWD vehicle engine mount to the frame bolts. ^ Tighten the AWD vehicle engine mount to frame bolts to 59 Nm (44 ft. lbs.). 2. Install the RWD vehicle right side engine mount, the bolts, and the nuts to the frame. ^ Tighten the engine mount to frame bolts to 47 Nm (35 ft. lbs.). ^ Tighten the engine mount to frame nuts to 42 Nm (31 ft. lbs.). 3. Install the engine mount bracket to the engine. 4. Install the engine mount bracket bolts. ^ Tighten the engine mount bracket bolts to 64 Nm (47 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1888 5. Lower the engine. 6. Install the engine mount through- bolt and the nut. ^ Tighten the engine mount through-bolt nuts to 68 Nm (50 ft. lbs.). 7. Install the starter. 8. Install the right fender wheelhouse extension. 9. Install the right front tire. 10. Lower the vehicle. 11. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Right Idler Pulley: Service and Repair Drive Belt Idler Pulley - Right Drive Belt Idler Pulley Replacement - Right Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt idler pulley bolt. 3. Remove the drive belt idler pulley from the generator mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the drive belt idler pulley and bolt to the generator mounting bracket. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Right > Page 1893 Idler Pulley: Service and Repair Drive Belt Idler Pulley - Without Air Conditioning Drive Belt Idler Pulley Replacement - without Air Conditioning Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt idler pulley bolt. 3. Remove the drive belt idler pulley from the power steering pump mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the drive belt idler pulley and bolt to the power steering pump mounting bracket. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Lubrication System Oil Pressure - at 1,000 RPM ................................................................................................................ ........................................................ 42 kPa (6 psi) Oil Pressure - at 2,000 RPM ............................... ..................................................................................................................................... 125 kPa (18 psi) Oil Pressure - at 4,000 RPM ......................................................................................................... ........................................................... 166 kPa (24 psi) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1898 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2 - 3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: ^ Engine oil diluted by moisture or unburned fuel mixtures ^ Improper engine oil viscosity for the expected temperature ^ Incorrect or faulty oil pressure gage sensor ^ Incorrect or faulty oil pressure gage ^ Plugged oil filter ^ Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: Specification 7.1. 42 kPa (6 psi) minimum, at 1,000 RPM 7.2. 125 kPa (18 psig) minimum, at 2,000 RPM 7.3. 166 kPa (24 psig) minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: ^ Oil pump worn or dirty ^ Malfunctioning oil pump pressure relief valve ^ Oil pump screen loose, plugged, or damaged ^ Excessive bearing clearance ^ Cracked, porous or restricted oil galleries ^ Engine block oil gallery plugs missing or incorrectly installed ^ Broken valve lifters Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the engine cover. 2. Remove the oil level indicator. 3. Remove the bolt holding the oil level indicator tube to the transmission fluid fill tube. 4. Remove the upper half of the oil level indicator tube from the lower half. 5. Clean the old sealer from the tube. 6. Remove the oil level indicator tube bolt. 7. Remove the oil level indicator tube from the engine using a twisting motion. 8. Clean the old sealer from the oil level indicator tube and the engine block. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 1902 Installation Procedure 1. Install the lower half of the oil level indicator tube to the engine. 2. Apply sealer, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, on the upper oil level indicator tube to the area where the tube fits into the lower half. 3. Install the oil level indicator tube upper half to the lower half. Notice: Refer to Fastener Notice in Service Precautions. 4. Secure the engine oil level indicator tube to the transmission fluid fill tube with the bolt. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 5. Install the oil level indicator. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1907 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1908 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1911 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Grade ............................................................... ......................................................................................................................................... 5W-30 (preferred) Above -18° C (0° F) ........................................................................................................... ........................................................ 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1912 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil in a suitable container. 3. Remove the engine oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the engine oil filter gasket with clean engine oil. 2. Install the engine oil filter. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1913 3. Follow the tightening instructions on the oil filter. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the drain plug to the oil pan. ^ Tighten the oil pan plug to 25 Nm (18 ft. lbs.). 5. Remove the safety stands and lower the vehicle. 6. Fill the engine with the proper capacity and quality of engine oil. 7. Operate the engine, check for leaks and oil pressure. 8. Check the oil level and add as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1918 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil in a suitable container. 3. Remove the engine oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the engine oil filter gasket with clean engine oil. 2. Install the engine oil filter. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1919 3. Follow the tightening instructions on the oil filter. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the drain plug to the oil pan. ^ Tighten the oil pan plug to 25 Nm (18 ft. lbs.). 5. Remove the safety stands and lower the vehicle. 6. Fill the engine with the proper capacity and quality of engine oil. 7. Operate the engine, check for leaks and oil pressure. 8. Check the oil level and add as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Replacement Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Oil Filter Adapter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the oil filter. 4. Disconnect the engine oil cooler pipes from the oil filter adapter. 5. Remove the oil filter adapter. Installation Procedure 1. Install the oil filter adapter with a NEW gasket. 2. Install the engine oil cooler pipes to the oil filter adapter. 3. Install the oil filter. 4. Lower the vehicle. 5. Operate the vehicle and check for leaks. 6. Check the oil level and add as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Replacement > Page 1924 Oil Filter Adapter: Service and Repair Oil Filter Bypass Valve Oil Filter Bypass Valve Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the oil filter. 4. Remove the oil filter adapter. 5. Using a suitable prying tool remove the oil filter bypass valve. 6. Clean and inspect valve bore for damage. Installation Procedure Caution: Refer to Safety Glasses Caution in Service Precautions. 1. Install a NEW oil filter bypass valve using the following procedure: 1.1. Use a brass drift that is the same diameter as the outside diameter of the oil filter bypass valve. 1.2. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. 1.3. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart. 2. Install the oil filter adapter. 3. Install the oil filter. 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Tighten the oil pan bolts and nuts in sequence (1-12). Oil Cooler Pipe Bracket Bolt to Oil Pan ............................................................................................................................................... 10 Nm (89 inch lbs.) Oil Pan Baffle Bolt .......................................................................................................... .................................................................... 12 Nm (106 inch lbs.) Oil Pan Bolt and Nut .................... ............................................................................................................................................................ 25 Nm (18 ft. lbs.) Oil Pan Drain Plug ................................................................................................. ................................................................................... 25 Nm (18 ft. lbs.) Transmission Bolt to Oil Pan ...................................................................................................................................................... .............. 47 Nm (35 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1928 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Disconnect the battery negative cable. 2. Remove the oil level indicator. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the oil pan drain plug and drain the engine oil into a suitable container. 5. Remove the oil filter. 6. Remove the bolt holding the oil cooler pipes bracket to the oil pan. 7. Remove the oil filter adapter. 8. Remove the bolt holding the bracket for the starter wiring harness and the transmission cooler pipes. 9. Remove the crankcase position sensor wiring harness from the retainer. 10. Remove the starter. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1929 11. Remove the transmission cover. 12. Remove the access plugs for the oil pan rear nuts. 13. Remove the transmission to oil pan bolts. 14. Remove the oil pan from the engine. 15. Clean all sealing surfaces on the engine and the oil pan. Installation Procedure Notice: Any time the transmission and the engine oil pan are off of the engine at the same time, install the transmission before the oil pan. This is to allow for the proper oil pan alignment. Failure to achieve the correct oil pan alignment can result in transmission failure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1930 1. Install the oil pan to the engine. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission to oil pan bolts and nuts. ^ Tighten the bolts to 47 Nm (35 ft. lbs.). 3. Install the access plugs for the oil pan rear nuts. 4. Install the transmission cover. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 5. Install the starter motor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1931 6. Install the bolt holding the bracket for the starter wiring harness and the transmission cooler pipes. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 7. Install the CKP sensor wiring harness in the retainer. 8. Install the oil filter adapter. 9. Install the oil cooler pipes bracket bolt. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 10. Install the oil filter. 11. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 12. Lower the vehicle. 13. Fill the crankcase with engine oil. 14. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1935 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1936 Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J 41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Page 1940 1. Install the engine oil pressure gage sensor fitting, if removed. Tighten 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J 41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Lubrication System Oil Pressure - at 1,000 RPM ................................................................................................................ ........................................................ 42 kPa (6 psi) Oil Pressure - at 2,000 RPM ............................... ..................................................................................................................................... 125 kPa (18 psi) Oil Pressure - at 4,000 RPM ......................................................................................................... ........................................................... 166 kPa (24 psi) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1945 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2 - 3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: ^ Engine oil diluted by moisture or unburned fuel mixtures ^ Improper engine oil viscosity for the expected temperature ^ Incorrect or faulty oil pressure gage sensor ^ Incorrect or faulty oil pressure gage ^ Plugged oil filter ^ Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: Specification 7.1. 42 kPa (6 psi) minimum, at 1,000 RPM 7.2. 125 kPa (18 psig) minimum, at 2,000 RPM 7.3. 166 kPa (24 psig) minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: ^ Oil pump worn or dirty ^ Malfunctioning oil pump pressure relief valve ^ Oil pump screen loose, plugged, or damaged ^ Excessive bearing clearance ^ Cracked, porous or restricted oil galleries ^ Engine block oil gallery plugs missing or incorrectly installed ^ Broken valve lifters Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Lower Manifold Intake Manifold: Specifications Lower Manifold LOWER INTAKE MANIFOLD TORQUE AND TIGHTENING SEQUENCE NOTE: Proper lower intake manifold fastener tightening sequence (as shown in the image) and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3-step method below. Failing to do so may distor the crankshaft bearing bore alignment and cause damage to the crankshaft bearings. 1. Tighten the bolts on the first pass in sequence (1-8) to 3 Nm (27 lb.in.). 2. Tighten the bolts on the second pass in sequence (1-8) to 12 Nm (106 lb.in.). 3. Tighten the bolts on the final pass in sequence (1-8) to 15 Nm (11 lb.ft.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Lower Manifold > Page 1952 Intake Manifold: Specifications Upper Manifold UPPER INTAKE MANIFOLD TORQUE AND TIGHTENING SEQUENCE Install the 6 injectors into the proper lower intake manifold bores in proper sequence as shown in the image (3, 5, 1, 2, 4, 6) TIGHTEN 1. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 lb.in). 2. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 lb.in). Throttle Body Attaching Studs ............................................................................................................. ......................................................... 9 Nm (80 lb.in) Intake Manifold Surface Flatness ......................................................................................................................................................... 0.10 mm (0.004 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) Intake Manifold: Service and Repair Intake Manifold Assemble (LU3) UPPER INTAKE MANIFOLD ASSEMBLE Important: During the removal of the fuel injector assembly, the retainers that hold the injectors into the intake manifold may become worn. This is OK. Upon installation of the upper intake manifold, the injectors will be held fully seated, thus keeping them from backing out of the lower intake manifold. - If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel meter body bracket bolt. 1. Install the fuel meter body bracket and bolt. 2. Tighten the fuel meter bracket bolt to 10 Nm (89 lb.in.) Important: All injector lines must face forward as the fuel meter body is snapped into the bracket. Also, the number three fuel tube must be positioned behind the number one fuel tube to eliminate interference with the upper intake manifold when installed. 3. Install the fuel meter body into the fuel meter body bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1955 4. Install the 6 injectors into the proper lower intake manifold bores in proper sequence (3, 5, 1, 2, 4, 6). 5. Inspect the injectors in order to ensure that they are firmly seated and locked in the lower intake manifold bores. 6. Ensure that the electrical connections of the injectors are positioned so that they do not interfere with each other, and are pointing towards the center of the intake manifold. Rotate the electrical connector inboard if necessary. Also, ensure there is no tension on the injector wires. 7. Install a NEW upper intake manifold to lower intake manifold gasket into the groove of the upper intake manifold. 8. Install the upper intake manifold onto the lower intake manifold. 9. If reusing the fasteners, apply threadlock GM P/N 1234582 (Canadian P/N 10953489) or equivalent, to the threads of the upper intake manifold attaching studs. 10. Install the upper intake manifold attaching studs. 11. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 lb.in.) 12. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 lb.in.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1956 13. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the evaporative emission (EVAP) canister purge solenoid valve studs. 14. Install the EVAP canister purge solenoid valve and studs. 15. Tighten the EVAP canister purge solenoid valve studs to 10 Nm (89 lb.in.) 16. Install the engine wiring harness bracket and nut. 17. Tighten the engine wiring harness bracket nut to 12 Nm (106 lb. in.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1957 18. Install the NEW fuel seals (8), black O-rings, into the fuel meter body. 19. Install the NEW spacer rings (7), flat washers, into the fuel meter body. 20. Install the NEW fuel seals (6), yellow O-rings, into the fuel meter body. 21. Install the NEW fuel seal retainers (5) into the fuel meter body. 22. Install the fuel pipe (3) into the fuel meter body. 23. Install the fuel pipe retainer bracket (2) onto the fuel pipe. 24. Install the fuel pipe retainer bracket nuts (1). 25. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel pipe bolt. 26. Install the fuel pipe bolt (4). 27. Tighten the fuel pipe bracket nuts to 3 Nm (27 lb.in.) 28. Tighten the fuel pipe bolt to 6 Nm (53 lb.in.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1958 29. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP sensor. 30. Apply a small amount, approximately 1 drop of clean engine oil to the MAP sensor seal. 31. Install the MAP sensor into the upper intake manifold. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1959 32. Install the ignition coil and studs. 33. Tighten the ignition coil studs to 12 Nm (106 lb.in.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1960 34. If reusing the engine coolant temperature (ECT) sensor plug (1) or the ECT sensor (2), if equipped, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the ECT sensor plug (1) or the ECT sensor (2). 35. Install the ECT sensor or plug, if equipped, into the front of the lower intake manifold. 36. Tighten the ECT sensor or plug to 20 Nm (15 lb.ft) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1961 37. Install the engine coolant thermostat. 38. Install the water outlet (1 or 2). 39. Install the water outlet studs. 40. Tighten the water outlet studs to 25 Nm (18 lb.ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1962 41. Install a NEW throttle body gasket into the groove in the upper intake manifold. 42. Install the throttle body onto the upper intake manifold. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1963 43. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the throttle body attaching studs. 44. Install the throttle body attaching studs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1964 45. Install the accelerator control cable bracket, the studs, and the nuts. 46. Tighten the accelerator control bracket studs to the intake manifold to 6 Nm (53 lb.in.) 47. Tighten the accelerator control bracket nuts to 12 Nm (106 lb.in.) 48. Tighten the accelerator control cable bracket studs to the throttle body to 12 Nm (106 lb.in.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1965 Intake Manifold: Service and Repair Intake Manifold Installation INTAKE MANIFOLD INSTALLATION Notice: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage. 1. Apply a 4.0 mm (0.157 in.) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to the cylinder head side of the lower intake manifold gasket at each end. Important: The lower intake manifold gasket must be installed while the adhesive is still wet to the touch. 2. Install the lower intake manifold gasket onto the cylinder head. 3. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1966 Important: The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch. 4. Apply a 5.0 mm (0.197 in.) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to the front top of the engine block. 5. Extend the adhesive bead 13 mm (0.50 in.) onto each lower intake manifold gasket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1967 6. Apply a 5 mm (0.197 in.) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to the rear top of the engine block. 7. Extend the adhesive bead 13 mm (0.50 in.) onto each lower intake manifold gasket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1968 8. Install the lower intake manifold onto the engine block. 9. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the lower intake manifold bolts. 10. Install the lower intake manifold bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1969 Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3-step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. 11. Tighten the lower intake manifold bolts. - Tighten the bolts on the first pass in sequence (1-8) to 3 Nm (27 lb.in.) - Tighten the bolts on the second pass in sequence (1-8) to 12 Nm (106 lb.in.) - Tighten the bolts on the final pass in sequence (1-8) to 15 Nm (11 lb.ft.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1970 12. Correct the evaporative emission (EVAP) canister solenoid valve harness. 12.1- Push the elbow inward until the quick connect snaps into place. 12.2- Pull the elbow outward in order to ensure proper connection. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1971 Intake Manifold: Service and Repair Intake Manifold Replacement - Lower Intake Manifold Replacement - Lower Removal Procedure 1. Disconnect the battery negative cable. 2. Remove the engine cover. 3. Drain the cooling system. 4. Remove the air cleaner assembly. 5. Remove the air cleaner outlet duct from the throttle body assembly. 6. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. 7. Perform this step if the vehicle is equipped with a cruise control. Disconnect the cruise control cable from the throttle shaft, and from the accelerator control cable bracket. 8. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover. 9. Remove the nut holding the A/C hose bracket to the intake manifold stud, if equipped. 10. Remove the nut holding the engine wiring harness bracket to the intake manifold stud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1972 11. Disconnect the following electrical connectors: ^ The A/C compressor clutch, if equipped (1) ^ The A/C high pressure cutoff switch, if equipped (5) ^ The throttle position (TP) sensor (2) ^ The idle air control (IAC) motor (3) ^ The fuel meter body assembly connector (4) 12. Disconnect the following electrical connectors: ^ The manifold absolute pressure (MAP) sensor (4) ^ The EVAP canister purge solenoid valve (1) 13. Remove the ground wire from the stud at the water outlet. 14. Remove the nut, and remove the engine wiring harness bracket from the stud, at the EVAP canister purge solenoid valve. 15. Move and secure the engine wire harness out of the way. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1973 16. Remove the EVAP canister purge valve. 17. Remove the radiator inlet hose at the water outlet. 18. Remove the heater hose from the intake manifold. 19. Remove the water pump inlet hose from the intake manifold. 20. Disconnect the vacuum hose from the intake manifold. 21. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1974 22. Remove the accelerator control cable bracket from the throttle body and the intake manifold. 23. Remove the distributor. 24. Disconnect the fuel supply, and disconnect the return pipes, at the rear of the intake manifold. 25. Remove the ignition control module (ICM). 26. In order to remove the front intake manifold bolt, perform the following steps: 26.1. Remove the drive belt. 26.2. Remove the A/C compressor side brace. 26.3. Loosen the nut for the power steering pump rear bracket. 26.4. Remove the oil filler tube bracket bolt and the oil filler tube. 26.5. Remove the bolts and the nut for the power steering pump mounting bracket. 26.6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket. 26.7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold. 27. Remove the lower intake manifold. 28. Clean all sealing surfaces and the intake manifold. 29. If the intake manifold requires replacement, See: Intake Manifold Installation Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1975 1. Install the lower intake manifold, See: Intake Manifold Installation 2. Reposition the power steering pump mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pump mounting bracket three bolts and the nut. ^ Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 Nm (30 ft. lbs.). 4. Install A/C compressor side brace and bolts. 4.1. Tighten the A/C compressor side brace bolt to 25 Nm (18 ft. lbs.). 4.2. Tighten the side brace bolt to the generator bracket to 25 Nm (18 ft. lbs.). 5. Install the oil filler tube and bolt. ^ Tighten the oil filler tube bolt to 25 Nm (18 ft. lbs.). 6. Install the drive belt. 7. Install the EVAP canister purge valve. 8. Install the fuel supply and return pipes to the rear of the intake manifold. Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center. 9. Remove the spark plug for number one cylinder. 10. Rotate the crankshaft until number one cylinder is in the compression stroke. 11. Align the 2 reference marks on the crankshaft balancer (1, 4) with the 2 alignment marks (2, 3) on the front cover. 12. Install the spark plug. 13. Install the distributor. 14. Install the ICM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1976 15. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. ^ Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.). 16. Install the vacuum hose to the intake manifold. 17. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket. ^ Tighten the transmission fluid fill tube bolt 6 Nm (53 inch lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1977 18. Install the water pump inlet hose to the intake manifold. 19. Install the heater hoses. 20. Install the radiator inlet hose to the water outlet. 21. Position the engine wiring harness. 22. Connect the following electrical connectors: ^ The A/C compressor clutch, if equipped (1) ^ The A/C high pressure cutoff switch, if equipped (5) ^ The throttle position (TP) sensor (2) ^ The idle air control (IAC) motor (3) ^ The fuel meter body assembly connector (4) 23. Connect the following electrical connectors: ^ The manifold absolute pressure (MAP) sensor (4) ^ The EVAP canister purge solenoid valve (1) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1978 24. Install the ground wire and the nut to the water outlet stud. ^ Tighten the ground wire nut to 19 Nm (14 ft. lbs.). 25. Install the nut and the engine wiring harness bracket to the stud for the EVAP canister purge valve. ^ Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.). 26. Install the nut and the engine wiring harness bracket to the intake manifold stud. ^ Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.). 27. Install the nut and the A/C hose bracket to the intake manifold stud, if equipped. ^ Tighten the A/C hose bracket nut to 5 Nm (44 inch lbs.). 28. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover. 29. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. 30. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1979 31. Refill the cooling system. 32. Install air cleaner outlet duct to the throttle body. 33. Install the air cleaner assembly. 34. Connect the battery negative cable. 35. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1980 Intake Manifold: Service and Repair Upper Intake Manifold Replacement Intake Manifold Replacement - Upper Removal Procedure Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold. 1. Remove the engine cover. 2. Remove the air cleaner outlet duct from the throttle body. 3. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. 4. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket. 5. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover. 6. Remove the nut holding the A/C hose bracket, if equipped to the intake manifold stud. 7. Remove the A/C hose bracket from the stud. 8. Remove the nut holding the engine wiring harness bracket to the intake manifold stud. 9. Remove the engine wiring harness bracket from the stud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1981 10. Disconnect the following electrical connectors: ^ The A/C compressor clutch, if equipped (1) ^ The A/C high pressure cutoff switch, if equipped (5) ^ The throttle position (TP) sensor (2) ^ The idle air control (IAC) motor (3) ^ The fuel meter body assembly connector (4) 11. Disconnect the following electrical connectors: ^ The manifold absolute pressure (MAP) sensor (4) ^ The EVAP canister purge solenoid valve (1) 12. Remove the engine wiring harness bracket from the stud at the EVAP canister purge solenoid valve. 13. Move and secure the engine wiring harness out of the way. 14. Remove the EVAP canister purge valve to Evaporative Emission (EVAP) Canister Purge Valve Replacement. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1982 15. Disconnect the vacuum hose from the intake manifold. 16. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket. 17. Remove the accelerator control cable bracket from the throttle body and the intake manifold. 18. Remove the fuel lines from the fuel meter body assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1983 19. Remove the studs for the upper intake manifold. 20. Remove the upper intake manifold. 21. Remove the upper intake manifold gasket from the groove. 22. Discard the gasket. 23. Remove the seal from the fuel meter body assembly. 24. Discard the seal. Important: Do not immerse the assembled upper intake manifold in cleaning solvent. 25. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent. 26. Inspect the upper intake manifold for the following: ^ Cracks or other damage to the exterior ^ Cracking or damage to the gasket grooves ^ Loose or damaged bolt hole thread inserts Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1984 27. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold. 28. Remove and discard the seal. 29. Remove the throttle body if replacing the upper intake manifold. 30. Remove the MAP sensor if replacing the upper intake manifold. Installation Procedure 1. Install the throttle body, if removed. 2. Install the MAP sensor, if removed. 3. Install the PCV valve cover, if removed, using the following procedure: 3.1. Install a NEW seal (O-ring) on the PCV valve cover. 3.2. Lubricate the seal with clean engine oil. 3.3. Install the PCV valve cover in the upper intake manifold. 3.4. Turn and lock the PCV valve cover in position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1985 4. Install a NEW seal on the fuel meter body assembly. 5. Lubricate the seal with clean engine oil. 6. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold. 7. Install the upper intake manifold onto the lower intake manifold. See: Intake Manifold Assemble (LU3) 8. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the upper intake manifold attaching studs. 9.1. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 inch lbs.). 9.2. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 inch lbs.). 10. Install the fuel lines to the fuel meter body assembly. 11. Install the EVAP canister purge valve. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1986 12. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. ^ Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.). 13. Connect the vacuum hose to the intake manifold. 14. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket. ^ Tighten the transmission fluid fill tube bolt 6 Nm (53 inch lbs.). 15. Position the engine wiring harness. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1987 16. Connect the following electrical connectors: ^ The A/C compressor clutch, if equipped (1) ^ The A/C high pressure cutoff switch, if equipped (5) ^ The throttle position (TP) sensor (2) ^ The idle air control (IAC) motor (3) ^ The fuel meter body assembly connector (4) 17. Connect the following electrical connectors: ^ The manifold absolute pressure (MAP) sensor (4) ^ The EVAP canister purge solenoid valve (1) 18. Install the engine wiring harness bracket and nut to the intake manifold stud. ^ Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.). 19. Install the A/C hose bracket and nut, if equipped to the intake manifold stud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Assemble (LU3) > Page 1988 ^ Tighten the A/C hose bracket nut to 5 Nm (44 inch lbs.). 20. Install the engine wiring harness bracket and the nut onto the stud at the EVAP canister purge solenoid valve. ^ Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.). 21. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover. 22. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. 23. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. 24. Install the air cleaner outlet duct to the throttle body assembly. 25. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement ^ Tools Required J 35621-B Rear Main Seal Installer Removal Procedure 1. Remove the transmission assembly. 2. Remove the engine flywheel. 3. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing. 4. Discard the crankshaft rear oil seal. 5. Clean off any dirt or rust in the area. Installation Procedure 1. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing. 2. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange. 3. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin. 4. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface. 5. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal. Minor imperfections may be removed with a fine grade emery cloth. Important: DO NOT allow oil or any other lubricants to contact the seal lip surface of the crankshaft rear oil seal. 6. Remove the sleeve from the crankshaft rear oil seal. 7. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal. 8. Install the crankshaft rear oil seal onto the J 35621-B. 9. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1993 Notice: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail. 10. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. 10.1. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. 10.2. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the crankshaft rear oil seal. 11. Remove the J 35621-B from the crankshaft. 12. Wipe off any excess engine oil with a clean rag. 13. Install the engine flywheel. 14. Install the transmission assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Cover Front Oil Seal Removal Procedure 1. Remove the crankshaft balancer. 2. Use a suitable prying tool to remove the crankshaft front oil seal. 3. Inspect the engine front cover seal bore for damage. 4. Inspect the crankshaft balancer seal area. Installation Procedure ^ Tools Required J 35468 Crankshaft Aligner/Seal Installer Important: The engine front cover is a plastic composition. 1. Lubricate the exterior of the crankshaft front oil seal with clean engine oil. 2. Use the J 35468 with a hammer in order to install the crankshaft front oil seal. 3. Inspect to ensure the crankshaft front oil seal is flush and square to the engine front cover. 4. Install the crankshaft balancer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 5892-D Valve Spring Compressor Removal Procedure 1. Remove the valve rocker arm cover. ^ Refer to Valve Rocker Arm Cover Replacement - Left ^ Refer to Valve Rocker Arm Cover Replacement - Right 2. Remove the required valve rocker arms. 3. Remove the required spark plugs. 4. Install the J 22794 into the spark plug hole. 5. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 6. Remove a bolt from a valve rocker arm. 7. Install a flat washer on the bolt. 8. Install the bolt in the valve rocker arm bolt hole for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 9. Use the J 5892-D in order to compress the valve spring. 9.1. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9.2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2000 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use J 38606 when J 5892-D will not fit. 11. Remove the valve keys (1). 12. Carefully release the valve spring tension. 13. Remove the J 5892-D or J 38606. 14. Remove the valve spring cap (2) and valve spring (3). 15. Remove the valve stem oil seal (4). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2001 1. Install the valve seals (4). 2. Install the valve spring (3). 3. Install the valve spring cap (2) on the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 4. To press the valve spring (3) use the J 5892-D Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 5. Use the J 38606 if the clearance does not permit use of the J 5892-D 6. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 7. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 8. Remove the J 5892-D or the J 38606. 8.1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 8.2. Tap the end of the valve stem with a plastic faced hammer in to seat the valve stem keys, if necessary. 9. Remove the J 22794 10. Install the spark plugs. 11. Install the valve rocker arms to the cylinder head. 12. Install the valve rocker arm cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2006 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2007 Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J 41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 2011 1. Install the engine oil pressure gage sensor fitting, if removed. Tighten 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J 41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Engine - Balance Shaft Rattling Noises (Cancellation) Balance Shaft: Technical Service Bulletins Engine - Balance Shaft Rattling Noises (Cancellation) Bulletin No.: 00-06-01-023C Date: August 30, 2006 TECHNICAL Subject: Engine/Balance Shaft "Rattle" Noise Models: 1992-2003 Chevrolet and GMC C/K, S/T, M/L, G and P Models 1992-2001 Oldsmobile Bravada with 4.3 L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to cancel this bulletin. Please discard Corporate Bulletin Number 00-06-01-023B (Section 06 -- Engine/Propulsion System). Technicians should refer to Corporate Bulletin Number 03-06-01-024C for information on engine/balance shaft "rattle" noise concerns. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Page 2017 Balance Shaft: Service and Repair Balance Shaft Replacement Removal Procedure 1. Remove the radiator. 2. Remove the A/C condenser, if equipped. 3. Remove the valve lifter pushrod guide. 4. Remove the camshaft timing chain and sprockets. Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 5. Remove the balance shaft. 6. Clean and inspect the balance shaft. Installation Procedure 1. Install shaft. 2. Install the camshaft timing chain and the camshaft sprocket. 3. Install the crankshaft position reluctor ring and the engine front cover. 4. Install the valve lifter pushrod guide. 5. Install the A/C condenser, if equipped. 6. Install the radiator. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Replacement Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Notice: In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt. 3. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft. Notice: Align the timing marks before removing the timing chain. If it is necessary to turn either the camshaft or the crankshaft with the timing chain removed, loosen or remove the valve rocker arms. Turning either the crankshaft or camshaft with the timing chain removed may cause the pistons to contact the valves, resulting in damage. 4. Rotate the crankshaft until: 4.1. The timing marks on both sprockets line up. 4.2. The number four cylinder is at top dead center (TDC) of the compression stroke. 5. Remove the timing chain and sprockets. 6. Clean and inspect the timing chain and sprockets. Installation Procedure 1. Install the timing chain and the sprockets. 2. Remove the bolt from the crankshaft. Notice: Do not reuse the engine front cover. Oil leaks may result. 3. Install the engine front cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's Timing Chain Tensioner: Customer Interest Engine - Engine Rattle at 1,800-2,200 RPM's Bulletin No.: 03-06-01-024C Date: August 30, 2006 TECHNICAL Subject: Rattle Noise In Engine (Install Timing Tensioner Kit) Models: 1996-2003 Chevrolet Astro, Blazer, Express, S-10, Silverado and P Models 1996-2003 GMC Jimmy, Safari, Savana, Sierra, Sonoma 1996-2001 Oldsmobile Bravada with 4.3L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 03-06-01-024B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a rattle-type noise coming from the engine at approximately 1800 to 2200 RPMs. Cause The spark, rattle-type noise may be caused by torsional vibration of the balance shaft. Correction If detonation noise is present, perform detonation/spark knock diagnostics first. Install a new tensioner assembly kit using the procedure below. Remove the engine front cover. Refer to SI for engine front cover removal procedure. Remove the crankshaft sensor reluctor ring and line up the timing marks on the crank gear and cam shaft gear. Remove the camshaft gear and chain. For model years 1996-1998, remove the crankshaft sprocket using J 5825-A. Pull the shipping pin and discard. Remove the nylon timing chain tensioner blade from the timing chain tensioner bracket. Position the bracket on the front of the engine. The upper two attaching holes of the bracket will line up with the center two engine front cover bolt holes. The lower bracket holes will line up with the engine front cover alignment holes. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2029 Use a hammer and the J 46165 Pin Driver to install the dowel pins through the two lower holes in the bracket and into the engine block. Make sure that the bracket is held firmly in place before proceeding. For model years 1996-1998, install a roller-type timing chain set. Install the crankshaft sprocket using the J 5590 Crankshaft Gear Installer. Install the timing chain around the crankshaft sprocket and position the timing chain to the driver's side of the engine. Install the nylon timing chain tensioner guide onto the timing chain tensioner bracket pin and position the top of the guide under the tab at the top of the bracket. Install the camshaft sprocket into the chain and then to the camshaft. Install the bolts finger-tight. Make sure the timing marks are aligned, then tighten the camshaft sprocket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Install the crankshaft reluctor ring. Install the engine front cover and place a washer under the two center cover bolts that extend through the tensioner bracket. These washers are required to maintain the proper crush on the engine front cover seal. Tighten Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2030 Tighten the bolts to 12 N.m (106 lb in). Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2031 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's Timing Chain Tensioner: All Technical Service Bulletins Engine - Engine Rattle at 1,800-2,200 RPM's Bulletin No.: 03-06-01-024C Date: August 30, 2006 TECHNICAL Subject: Rattle Noise In Engine (Install Timing Tensioner Kit) Models: 1996-2003 Chevrolet Astro, Blazer, Express, S-10, Silverado and P Models 1996-2003 GMC Jimmy, Safari, Savana, Sierra, Sonoma 1996-2001 Oldsmobile Bravada with 4.3L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 03-06-01-024B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a rattle-type noise coming from the engine at approximately 1800 to 2200 RPMs. Cause The spark, rattle-type noise may be caused by torsional vibration of the balance shaft. Correction If detonation noise is present, perform detonation/spark knock diagnostics first. Install a new tensioner assembly kit using the procedure below. Remove the engine front cover. Refer to SI for engine front cover removal procedure. Remove the crankshaft sensor reluctor ring and line up the timing marks on the crank gear and cam shaft gear. Remove the camshaft gear and chain. For model years 1996-1998, remove the crankshaft sprocket using J 5825-A. Pull the shipping pin and discard. Remove the nylon timing chain tensioner blade from the timing chain tensioner bracket. Position the bracket on the front of the engine. The upper two attaching holes of the bracket will line up with the center two engine front cover bolt holes. The lower bracket holes will line up with the engine front cover alignment holes. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2037 Use a hammer and the J 46165 Pin Driver to install the dowel pins through the two lower holes in the bracket and into the engine block. Make sure that the bracket is held firmly in place before proceeding. For model years 1996-1998, install a roller-type timing chain set. Install the crankshaft sprocket using the J 5590 Crankshaft Gear Installer. Install the timing chain around the crankshaft sprocket and position the timing chain to the driver's side of the engine. Install the nylon timing chain tensioner guide onto the timing chain tensioner bracket pin and position the top of the guide under the tab at the top of the bracket. Install the camshaft sprocket into the chain and then to the camshaft. Install the bolts finger-tight. Make sure the timing marks are aligned, then tighten the camshaft sprocket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Install the crankshaft reluctor ring. Install the engine front cover and place a washer under the two center cover bolts that extend through the tensioner bracket. These washers are required to maintain the proper crush on the engine front cover seal. Tighten Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2038 Tighten the bolts to 12 N.m (106 lb in). Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2039 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 2045 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 2062 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 2067 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 2068 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 2074 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 2091 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 2096 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 2097 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolt ...................................................................................................................... ............................................... 12 Nm (106 inch lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2101 Timing Cover: Service and Repair Engine Front Cover Replacement Removal Procedure 1. Remove the engine oil pan. 2. Remove the crankshaft balancer. 3. Remove the water pump. 4. Remove the crankshaft position (CKP) sensor. Notice: Do not reuse the engine front cover. Oil leaks may result. 5. Remove the engine front cover. 6. Discard the engine front cover. 7. Clean all sealing surfaces. Installation Procedure Notice: Do not reuse the engine front cover. Oil leaks may result. 1. Install the engine front cover. 2. Install the engine oil pan. Important: Do not reuse the original seal (O-ring) when installing the crankshaft position sensor to the engine front cover. Erratic engine operation may result. 3. Install the CKP sensor. 4. Install the water pump. 5. Install the crankshaft balancer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2107 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2108 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2109 Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2110 Steps 4-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2111 Step 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2112 Steps 9-12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2113 Steps 13-14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2114 Steps 15-18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2115 Steps 19-23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2128 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2134 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2135 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2141 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2142 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2146 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots 1/2 turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2155 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2156 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2162 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2163 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Page 2164 Distributor: Testing and Inspection DISTRIBUTOR INSPECTION 1. Remove the engine cover. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 2. Remove the 2 screws from the rotor. 3. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2167 4. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 5. Line up the square-cut hole in the vane wheel with the CMP sensor. 6. Remove the 2 screws that hold the camshaft position (CMP) sensor. 7. Discard the screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2168 8. Remove the CMP sensor. 9. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 10. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 11. Drive out the roll pin with a suitable punch. 12. Remove the driven gear from the distributor shaft. 13. Remove the round washer. 14. Remove the tang washer. 15. Remove the shim washer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2169 16. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Insert the sensor into the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2170 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2171 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2172 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2173 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. - Twist each spark plug wire 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2174 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2175 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2176 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2177 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 15. Install the engine cover. INSTALLATION PROCEDURE 2 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2178 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 2. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2179 3. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. 4. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 5. Install the distributor cap. 6. Install the new distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2180 Tighten Tighten the screws to 2.4 N.m (21 lb in). 7. Install the electrical connector to the distributor. 8. Install the spark plug wires to the distributor cap. 9. Install the ignition coil wire. Note the correct orientation of the wire boot. 10. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 11. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug: Electrical Specifications Spark Plug Wire Resistance................................................................................................................. ........................................................1,000 ohms per ft Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 2185 Spark Plug: Mechanical Specifications Spark Plug Gap 0.060 in. 1.52 mm Spark Plug Torque Used Heads 15 Nm 11 lb. ft. New Aluminum Heads 20 Nm 15 lb. ft. New Iron Heads 30 Nm 22 lb. ft. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2186 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ....................................................... AC Type 41-932 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2187 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2188 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2189 - Incorrect combustion - Reduced ignition system voltage output - Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2190 Spark Plug: Service and Repair REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.524 mm (0.060 in). 3. Hand start the spark plugs in the corresponding cylinders. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plugs. Tighten For used heads tighten the spark plugs to 15 N.m (11 lb ft). - For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). - For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 1. Install the spark plug wires. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2194 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml. (1 oz.) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Install the four bolts retaining the coolant pump. Water Pump Bolt ................................................................................................................................. ................................................. 45 Nm (33 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2201 Water Pump: Service and Repair Water Pump Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Drain the coolant from the radiator. 2. Remove the air cleaner assembly. 3. Remove the Mass Air Flow (MAF) sensor. 4. Remove the upper fan shroud. 5. Remove the drive belt. 6. Remove the fan and fan blade clutch assembly. 7. Remove the coolant pump pulley bolts and the pulley. 8. Disconnect the coolant bypass hose and clamps. 9. Disconnect the radiator outlet hose from the coolant pump. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2202 10. Remove the four coolant pump bolts. 11. Remove the coolant pump. 12. Remove the gaskets. Important: Make sure all of the gasket mating surfaces are free of burrs or other imperfections. 13. Inspect all of the parts. Replace the parts as necessary. Installation Procedure 1. Install the coolant pump gaskets. 2. Install the coolant pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the four bolts retaining the coolant pump. ^ Tighten the bolts to 45 Nm (33 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2203 4. Connect the coolant bypass hose and clamps. 5. Connect the radiator outlet hose to the coolant pump. 6. Install the coolant pump pulley and the bolts. ^ Tighten the coolant pump pulley bolts to 25 Nm (18 ft. lbs.). 7. Install the fan and fan blade clutch assembly. 8. Install the drive belt. 9. Install the upper fan shroud and the bolts. 10. Install the Mass Air Flow (MAP) sensor. 11. Install the air cleaner assembly. 12. Refill the radiator with coolant. 13. Start engine. After engine reaches normal operating temperature, check for coolant leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2209 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2210 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2211 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2212 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications With Rear Heater 16.5 qt (US) Note: Recheck fluid level after filling system. W/O Rear Heater 13.5 qt (US) Note: Recheck fluid level after filling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2215 Coolant: Fluid Type Specifications Engine Coolant 50/50 mixture of clean, drinkable water and use only GM Goodwrench DEX-COOL or Havoline DEX-COOL Coolant. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement Coolant Line/Hose: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Place a drain pan under the oil filter adapter. 2. Remove the engine oil cooler lines mounting bolt from the oil filter adapter assembly. 3. Remove the engine oil cooler lines from the oil filter assembly. 4. Remove the engine oil cooler line to engine bracket bolt. 5. Remove the engine oil cooler lines from the engine bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2220 6. Remove the oil cooler lines from the radiator. 7. Remove the engine oil cooler lines. 8. Clean all of the components with a suitable solvent. Dry the components with compressed air. 9. Inspect the following for damage or distortion: ^ The connector fittings ^ The connectors ^ The engine oil cooler lines Installation Procedure Important: Inspect the cooler line for a damaged or missing plastic cap. If the plastic cap is damaged or missing, replace it with a new plastic cap. 1. Install the engine oil cooler lines. 2. Install the engine oil cooler lines. 3. Install the engine oil cooler lines to the engine bracket. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the engine oil cooler line bracket bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2221 5. Install the engine oil cooler lines to the oil filter adapter assembly. 6. Install the engine oil cooler line bolt to the oil filter assembly. ^ Tighten the oil cooler lines to oil filter adapter assembly bolt to 35 Nm (26 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2222 Coolant Line/Hose: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 3. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors. 4. Clean all of the components in a suitable solvent, and dry them with compressed air. 5. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2223 1. Install a new retaining ring into each quick connector fitting. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2224 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. 6. Inspect and fill the engine oil to the proper level. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement Removal Procedure 1. Reposition the coolant recovery hose clamp from the coolant recovery reservoirs. 2. Remove the coolant recovery hose from the coolant recovery reservoirs. 3. Remove the push pin retainers. 4. Disconnect the electrical connectors from the windshield washer pumps. 5. Remove the windshield washer hoses from the windshield washer pumps. 6. Remove the coolant recovery reservoir and windshield washer assembly. 7. If replacing, separate the 2 reservoirs. 8. Drain the coolant in the reservoir. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Page 2228 Installation Procedure 1. Connect the electrical connectors to the windshield washer pumps. 2. Install the windshield washer hoses to the windshield washer pumps. 3. Install the coolant recovery reservoir and windshield washer assembly. 4. Install the push pin retainers. 5. Install the coolant recovery reservoir hose. 6. Reposition the coolant recovery hose clamp to the coolant recovery reservoirs. 7. Refill the coolant recovery reservoir. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis Fan Clutch: Technical Service Bulletins A/T - Intermittent Downshift/Slip/Cycling Diagnosis File In Section: 07 Transmission/Transaxle Bulletin No.: 99-07-30-016B Date: October, 2002 INFORMATION Subject: Diagnostic Information For Intermittent Transmission Downshift, Slip, Busy/cycling TCC or Noisy Cooling Fan Models: 1999-2000 Cadillac Escalade 2002-2003 Cadillac Escalade, Escalade EXT 1988-2003 Chevrolet Astro, Blazer, S-10, Silverado, Suburban 1989-2003 Chevrolet/Geo Tracker 1995-2003 Chevrolet Tahoe 1996-2003 Chevrolet Express 1988-1994 GMC S-15 1988-1999 GMC Suburban 1988-2003 GMC Safari, Sierra 1995-2003 GMC Sonoma, Yukon, Yukon XL 1996-2003 GMC Savana 1999-2001 GMC Envoy 1991-2001 Oldsmobile Bravada 2003 HUMMER H2 with Air Conditioning This bulletin is being revised to change the Model information and text. Please discard Corporate Bulletin Number 99-07-30-016A (Section 07 - Transmission/Transaxle) Some customers may comment that at times the transmission seems to slip, or that there is a loud roar from the engine with slow acceleration. This condition is most noticeable after the vehicle has sat idle for 12 or more hours, or on hot days when the A/C is on and the vehicle moves slowly with traffic. Typical comments from customers may include the following conditions: ^ Intermittent slipping ^ Intermittent downshift followed by an upshift, both with no apparent reason ^ Busyness or cycling of the TCC (torque converter clutch) at steady throttle conditions and on a level roadway ^ Noisy cooling fan The type of concern described above requires further definition. The customer should be asked the following questions: ^ Is the situation more pronounced with higher vehicle loads such as when pulling a trailer? ^ Do warmer ambient temperatures make the situation more pronounced? ^ When the condition occurred, did you have the A/C on, and were you driving in stop and go city traffic? ^ Does the condition exhibit itself on the first start-up after sitting more than eight hours? If the customer indicates that these conditions apply, and your observation confirms that the vehicle is operating properly, provide the customer with the vehicle operating description included at the end of this bulletin. Further action may not be necessary. A service procedure follows if further definition is required. Diagnostic Aids Cooling fan operation or the resulting sound varies. The cooling fan clutch may be described as a continuously variable clutch. If the vehicle engine is running, the fan blade is always turning unless the fan clutch is non-functional. The speed of the fan in relation to engine speed is temperature dependent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis > Page 2234 Maximum fan speed (air flow and related fan noise) through the engine compartment is experienced under two conditions. 1. When the vehicle sits in an unused condition for several hours, the viscous fluid within the thermostatic fan clutch assembly migrates and fully engages the clutch of the fan. After a short drive, the viscous fluid will migrate to the storage area in the fan clutch and the fan clutch will slip, reducing the noise (roar of the fan). This is normal thermostatic fan clutch operation. 2. When the engine is running, and the air being drawn by the fan or pushed through the radiator from the vehicle movement reaches a high enough temperature, the fan clutch will fully engage the fan clutch, drawing additional air through the radiator to lower the engine coolant temperature and A/C refrigerant temperature. When the cooling fan clutch fully engages, fan noise increases (for example; this is the same as switching an electric household fan from low to high speed). Some customers have interpreted this sound increase to be an increase in the engine RPM due to transmission downshift, transmission slipping, or TCC cycling. As the engine coolant temperature decreases, the fan clutch will begin to slip, lowering the actual speed of the fan blade and the resultant sound. Service Procedure When diagnosing an intermittent transmission downshift, slip, or busy/cycling TCC, follow these steps: 1. Verify the transmission fluid level and the fluid condition. Refer to the Automatic Transmission sub-section of the appropriate Service Manual. 2. Test drive the vehicle under the conditions described by the customer (ambient temperature, engine coolant temperature, trailering, etc.). It may be necessary to partially restrict airflow to the radiator in order to raise the engine coolant temperature to match the customer's conditions. 3. Monitor the engine RPM and the engine coolant temperature using a scan tool. 4. Listen for an actual increase in the engine RPM. Use either the vehicle tachometer (if equipped), the Tech 2 RPM or transmission slip speed as an indicator, rather than just the sound. If the engine RPM display on the tachometer or the Tech 2 increases, verify the scan tool RPM and coolant temperature readings. If the noise increase is due to the engagement of the fan, the engine RPM will not increase and the engine coolant temperature will begin to decrease after the fan engages. As the fan runs, the engine coolant temperature will drop and the fan will disengage, reducing noise levels. The engine RPM will not decrease. This cycle will repeat as the engine coolant temperature rises again. If the above procedure shows the condition to be cooling fan-related, no further action is necessary. The vehicle should be returned to the customer and the condition explained. If the above procedure shows the condition to be other than cooling fan-related, refer to the Automatic Transmission sub-section of the appropriate Service Manual for transmission diagnosis information. The following information regarding the operation of the engine cooling fan should be photocopied and given to the customer. Intermittent Transmission Downshift All light duty trucks are equipped with a thermostatic engine cooling fan. This fan is designed to provide greater fuel efficiency and quieter operation than a standard fan. These benefits are possible through the addition of a thermostatic clutch to the fan drive. When the engine is cool (it the engine has been run in the last few hours), the clutch allows the fan to "slip" or turn at a speed slower than the engine. By turning at a slower speed, the fan uses less horsepower, which saves fuel, and is quieter. When the engine temperature reaches a preset temperature or if the engine has not been run for several hours, the fan "engages" and turns at the same speed as the engine. "Engagement" of the fan provides increased airflow through the radiator to cool the engine. As the airflow increases, fan operation becomes clearly audible. This increase in noise can easily be mistaken for an increase in engine RPM and may be incorrectly blamed on the automatic transmission. When operating an unloaded vehicle in cooler ambient temperatures, the thermostatic clutch usually won't fully engage. However, if the vehicle is pulling a trailer, is heavily loaded or is operated at high ambient temperatures, the thermostatic fan clutch may cycle on and off as the engine coolant temperature rises and falls. The sound of fan operation under the conditions described above is a sign that the cooling system on your vehicle is working correctly. Replacement or modification of the cooling system or the transmission parts will not change or reduce the noise level. Attempts to reduce this noise may cause you, the customer, to believe that your vehicle is not reliable and will inconvenience you by causing your vehicle to be out of service. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis > Page 2235 DISCLAIMER Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 2236 Fan Clutch: Service and Repair Fan Clutch Replacement ^ Tools Required J 46406 Fan Clutch Wrench Removal Procedure Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced. 1. Remove the upper fan shroud. 2. Remove the fan clutch assembly using the J 46406 in a counter clockwise direction. 3. Remove the fan clutch assembly from the vehicle. 4. Remove the four bolts retaining the fan blade to the fan clutch. 5. Remove the fan blade from the fan clutch. Installation Procedure 1. Install the fan blade to the fan clutch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four bolts retaining the fan blade to the fan clutch. ^ Tighten the bolts to 33 Nm (24 ft. lbs.). 3. Install the fan clutch assembly using the J 46406 in a counter clockwise direction. ^ Tighten the fan clutch to 56 Nm (41 ft. lbs.). 4. Install the upper fan shroud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2241 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2242 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Drain the coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Disconnect the electrical connector. 5. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Refer to Component Fastener Tightening Notice in Service Precautions. 1. Coat the threads with sealer GM P/N 9985253 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2243 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor harness connector to the ECT sensor. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Upper Fan Shroud: Service and Repair Upper Fan Shroud Replacement - Upper Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the upper fan shroud bolts. 3. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper shroud bolts. ^ Tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the air cleaner assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Upper > Page 2248 Fan Shroud: Service and Repair Lower Fan Shroud Replacement - Lower Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the upper fan shroud bolts. 3. Remove the upper fan shroud. 4. Release the lower fan shroud clips. 5. Remove the lower fan shroud. Installation Procedure 1. Install the lower fan shroud. 2. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the upper shroud bolts. ^ Tighten the bolts to 15 Nm (11 ft. lbs.). 4. Install the air cleaner assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Locations > Page 2252 Coolant Bypass Valve Solenoid Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary Heater Control Valve: Service and Repair Coolant Bypass Valve Replacement - Auxiliary COOLANT BYPASS VALVE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. 4. Disconnect the electrical connector from the auxiliary coolant bypass valve (1). 5. Remove the vacuum hose from the auxiliary coolant bypass valve. 6. Remove the bolt that retains the auxiliary coolant bypass valve to the heater assembly. 7. Using the J 38185, reposition the auxiliary heater inlet hose (10) clamp from the auxiliary coolant bypass valve. 8. Remove the auxiliary heater inlet hose (10) from the auxiliary coolant bypass valve. 9. Using the J 38185, reposition the auxiliary outlet heater hose (2) clamp from the auxiliary coolant bypass valve. 10. Remove the auxiliary outlet heater hose (2) from the auxiliary coolant bypass valve. 11. Remove the auxiliary coolant bypass valve (1). INSTALLATION PROCEDURE 1. Install the auxiliary coolant bypass valve (1). 2. Install the auxiliary outlet heater hose (2) to the auxiliary coolant bypass valve. 3. Using the J 38185, reposition the auxiliary inlet heater hose clamp to the auxiliary coolant bypass valve. 4. Install the auxiliary heater outlet hose (10) to the auxiliary coolant bypass valve. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 2255 5. Using the J 38185, reposition the auxiliary heater hose clamp to the auxiliary coolant bypass valve. 6. Install the auxiliary coolant bypass valve to the heater assembly. 7. Install the bolt that retains the auxiliary coolant bypass valve to the heater assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 8. Connect the vacuum hose to the auxiliary coolant bypass valve. 9. Connect the electrical connector to the auxiliary coolant bypass valve. 10. Fill the cooling system. 11. Install the upper fan shroud. 12. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 2256 Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (Without RPO Code C36) HOT WATER BYPASS VALVE REPLACEMENT (WITHOUT RPO CODE C36) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. 4. Disconnect the vacuum hose from the water bypass valve. 5. Using the J 38185, reposition the heater inlet pipe (5) clamp from the water bypass valve. 6. Remove the heater inlet pipe from the water bypass valve. 7. Using the J 38185, reposition the heater outlet pipe (6) clamp from the water bypass valve. 8. Remove the heater outlet pipe from the water bypass valve. 9. Using the J 38185, reposition the heater inlet hose clamp from the water bypass valve. 10. Remove the heater inlet hose from the water bypass valve. 11. Using the J 38185, reposition the heater outlet hose clamp from the water bypass valve. 12. Remove the heater outlet hose from the water bypass valve. 13. Remove the bolt (3) that retains the water bypass valve (4) to the heater assembly. 14. Remove the water bypass valve. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 2257 1. Install the water bypass valve (4) to the heater assembly. 2. Install the bolt (3) that retains the water bypass valve to the heater assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 3. Install the heater outlet hose to the water bypass valve. 4. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve. 5. Install the heater inlet hose to the water bypass valve. 6. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve. 7. Install the heater outlet pipe to the water bypass valve. 8. Using the J 38185, reposition the heater inlet pipe (5) clamp to the water bypass valve. 9. Install the heater inlet pipe to the water bypass valve. 10. Using the J 38185, reposition the heater outlet pipe (6) clamp to the water bypass valve. 11. Connect the vacuum hose to the water bypass valve. 12. Fill the cooling system. 13. Install the upper fan shroud. 14. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 2258 Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (With RPO Code C36) HOT WATER BYPASS VALVE REPLACEMENT (WITH RPO CODE C36) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. 4. Disconnect the vacuum hose from the water bypass valve. 5. Using the J 38185, reposition the heater inlet hose (8) clamp from the water bypass valve. 6. Remove the heater inlet hose (8) from the water bypass valve. 7. Using the J 38185, reposition the heater outlet hose (7) clamp from the water bypass valve. 8. Remove the heater outlet hose (7) from the water bypass valve. 9. Using the J 38185, reposition the heater inlet hose (3) clamp from the water bypass valve. 10. Remove the heater inlet hose (3) from the water bypass valve. 11. Using the J 38185, reposition the heater outlet hose (4) clamp from the water bypass valve. 12. Remove the heater outlet hose (4) from the water bypass valve. 13. Using the J 38185, reposition the auxiliary heater outlet hose clamp from the water bypass valve. 14. Remove the auxiliary heater outlet hose (5) from the water bypass valve. 15. Using the J 38185, reposition the auxiliary heater outlet hose clamp (6) from the water bypass valve. 16. Remove the auxiliary heater outlet hose (10) from the water bypass valve. 17. Remove the bolt that retains the water bypass valve to the heater assembly. 18. Remove the water bypass valve. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 2259 1. Install the water bypass valve to the heater assembly. 2. Install the bolt (3) that retains the water bypass valve to the heater assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 3. Install the auxiliary heater outlet hose (5) to the water bypass valve. 4. Using the J 38185, reposition the auxiliary heater outlet hose clamp to the water bypass valve. 5. Install the auxiliary heater outlet hose (10) to the water bypass valve. 6. Using the J 38185, reposition the auxiliary heater outlet hose clamp (6) to the water bypass valve. 7. Install the heater outlet hose (4) to the water bypass valve. 8. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve. 9. Install the heater inlet hose (3) to the water bypass valve. 10. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve. 11. Install the heater outlet hose (7) to the water bypass valve. 12. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve. 13. Install the heater inlet hose (8) to the water bypass valve. 14. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve. 15. Connect the vacuum hose to the water bypass valve. 16. Fill the cooling system. 17. Install the upper fan shroud. 18. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2264 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2265 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Using the J 38185, reposition the outlet heater hose clamp at the heater core. 3. Remove the outlet heater hose from the heater core. 4. Using the J 38185, reposition the inlet heater hose clamp at the heater core. 5. Remove the inlet heater hose from the heater core. 6. Remove the screws (9) that retain the cover to the heater case assembly. 7. Remove the straps (8) that retain the heater core to the heater case assembly. 8. Remove the heater core (7) from the vehicle. INSTALLATION PROCEDURE 1. Install the heater core to the vehicle. 2. Install the straps that retain the heater core to the heater case assembly. 3. Install the screws that retain the heater core to the heater case assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 2268 Tighten the screws to 2 N.m (18 lb in). 4. Install the inlet heater hose to the heater core. 5. Using the J 38185, reposition the inlet heater hose clamp at the heater core. 6. Install the outlet heater hose to the heater core. 7. Using the J 38185, reposition the outlet heater hose clamp at the heater core. 8. Refill the cooling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 2269 Heater Core: Service and Repair Heater Core Replacement - Auxiliary HEATER CORE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Remove the body side front lower trim panel. 3. Remove the clamps from the auxiliary heater pipes. 4. Disconnect the auxiliary heater pipes from the auxiliary heater module. 5. Remove the screws and the band clamp from the right side of the heater core. 6. Remove the screw and the band clamp from the left side of the heater core. 7. Remove the heater core from the heater core case. IMPORTANT: Before removing the auxiliary heater module from the vehicle, be sure to place a protective cover on the floor in order to prevent coolant from leaking onto the carpet. 8. Remove the seals from the heater core. INSTALLATION PROCEDURE 1. Install the seals to the heater core. 2. Install the heater core into the heater core case. 3. Install the screw and the band clamp to the left side of the heater core. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws and the band clamp to 2 N.m (18 lb in). 4. Install the screws and the band clamp to the right side of the heater core. Tighten Tighten the screw and the band clamp to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 2270 5. Connect the auxiliary heater pipes from the auxiliary heater module. 6. Install the clamps to the auxiliary heater pipes. 7. Install the body side front lower trim panel. 8. Refill the system with engine coolant. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet Heater Hose: Service and Repair Heating Hoses Replacement - Inlet HEATING HOSES REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. 3. Remove the coolant recovery reservoir. 4. Remove the heater hose support clamp bolt (5). 5. Using the J 38185, reposition the inlet heater hose clamp from the heater core. 6. Remove the inlet heater hose (2) from the heater core. 7. Using the J 38185, reposition the inlet heater hose clamp from the water valve. 8. Remove the inlet heater hose (2) from the water bypass valve. INSTALLATION PROCEDURE 1. Install the inlet heater hose (2) to the water bypass valve. 2. Using the J 38185, reposition the inlet heater hose clamp to the water bypass valve. 3. Install the inlet heater hose (2) to the heater core. 4. Using the J 38185, reposition the inlet heater hose clamp to the heater core. 5. Install the heater hose support clamp to the heater core. 6. Install the heater hose support clamp bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 2275 Tighten Tighten the bolt to 4 N.m (35 lb in). 7. Install the coolant recovery reservoir. 8. Fill the cooling system. 9. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 2276 Heater Hose: Service and Repair Heating Hoses Replacement - Outlet HEATING HOSES REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. 3. Remove the coolant recovery reservoir. 4. Remove the heater hose support clamp bolt (5). 5. Using the J 38185, reposition the outlet heater hose clamp from the heater core. 6. Remove the outlet heater hose (3) from the heater core. 7. Using the J 38185, reposition the outlet heater hose clamp from the water bypass valve. 8. Remove the outlet heater hose (3) from the water bypass valve. INSTALLATION PROCEDURE 1. Install the outlet heater hose (3) to the water bypass valve. 2. Using the J 38185, reposition the outlet heater hose clamp to the water bypass valve. 3. Install the outlet heater hose (3) to the heater core. 4. Using the J 38185, reposition the outlet heater hose clamp to the heater core. 5. Install the heater hose support clamp to the heater core. 6. Install the heater hose support bolt (5). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 2277 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 7. Install the coolant recovery reservoir. 8. Fill the cooling system. 9. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 2278 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Front HEATER PIPE REPLACEMENT - AUXILIARY FRONT REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the front pipes (5) from the rear pipes. 4. Remove the bolts (3) that retain the front pipes (5) to the body. 5. Remove the clips (4) that retain the front pipes (5) to the body. 6. Remove the auxiliary heater front pipes (5) from the heater hoses (1). 7. Remove the auxiliary heater front pipes (5). INSTALLATION PROCEDURE 1. Install the auxiliary heater front pipes (5). 2. Connect the auxiliary heater front pipes (5) to the heater hoses (1). 3. Install the front pipe retaining clips (4) that retains the front pipes (5) to the body. 4. Install the bolts (3) that retain the front pipes (5) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the auxiliary heater front pipes (5) to the rear pipes. 6. Fill the cooling system with engine coolant. 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 2279 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Rear HEATER PIPE REPLACEMENT - AUXILIARY REAR REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Raise the vehicle.Refer to Vehicle Lifting. 3. Disconnect the auxiliary heater rear pipes from the heater core inlet and outlet tubes. 4. Disconnect the auxiliary heater rear pipes from the front pipes. 5. Remove the pipe retainers from the body. 6. Remove the auxiliary heater rear pipes. INSTALLATION PROCEDURE 1. Install the auxiliary heater rear pipes. 2. Install the pipe retainers to the body. 3. Connect the auxiliary heater rear pipes to the front pipes. 4. Connect the rear pipes to the auxiliary heater core inlet and outlet tubes. 5. Refill the cooling system with engine coolant. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Radiator: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2284 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2285 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2286 Radiator: Service and Repair Radiator Replacement ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the lower fan shroud. 3. Using the J 38185 reposition the radiator inlet hose clamp from the radiator. 4. Remove the radiator inlet hose from the radiator. 5. Using the J 38185 reposition the radiator outlet hose clamp from the radiator. 6. Remove the outlet hose from the radiator. 7. Remove the transmission oil cooler lines from the radiator. 8. Remove the engine oil cooler lines from the radiator. 9. Reposition the coolant recovery reservoir hose clamp from the coolant recovery reservoirs. 10. Remove the coolant recovery reservoir hose from the radiator filler neck. 11. Remove the grille. Important: It is not necessary to discharge the A/C system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2287 12. Remove the 4 bolts attaching the A/C condenser to the radiator. Reposition the condenser. 13. Remove the radiator. Installation Procedure 1. Install the radiator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 4 bolts attaching the A/C condenser to the radiator. ^ Tighten the bolt to 6 Nm (53 inch lbs.). 3. Install the grille. 4. Install the coolant recovery reservoir hose to the radiator filler neck. 5. Reposition the coolant recovery reservoir hose clamp to the coolant recovery reservoir. 6. Install the engine oil cooler lines to the connector fittings. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2288 7. Install the transmission oil cooler lines into the connector fittings. 8. Install the radiator inlet hose to the radiator. 9. Using the J 38185 reposition the radiator inlet hose clamp to the radiator. 10. Install the radiator outlet hose to the radiator. 11. Using the J 38185 reposition the radiator outlet hose clamp to the radiator. 12. Install the lower fan shroud. 13. Fill the cooling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing ^ Tools Required J 24460-01 Cooling System Pressure Tester Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Using the J 38185 reposition the radiator inlet hose clamp from the radiator. 4. Using the J 38185 reposition the radiator inlet hose clamp from the thermostat housing. 5. Remove the radiator inlet hose. Installation Procedure 1. Install the radiator inlet hose to the thermostat housing. 2. Using the J 38185 reposition the radiator inlet hose clamp to the thermostat housing. 3. Install the radiator inlet hose to the radiator. 4. Using the J 38185 reposition the radiator inlet hose clamp to the radiator. 5. Install the air cleaner assembly. 6. Fill the cooling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2296 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Using the J 38185 reposition the radiator outlet hose clamp from the radiator. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Using the J 38185 reposition the radiator outlet hose clamp from the water pump. 6. Remove the outlet hose. Installation Procedure 1. Install the radiator outlet hose to the water pump. 2. Using the J 38185 reposition the radiator outlet hose clamp to the water pump. 3. Lower the vehicle. Refer to Vehicle Lifting. 4. Install the radiator outlet hose to radiator. 5. Using the J 38185 reposition the radiator outlet hose clamp to the radiator. 6. Install the air cleaner assembly. 7. Fill the cooling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2302 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2303 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Drain the coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Disconnect the electrical connector. 5. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Refer to Component Fastener Tightening Notice in Service Precautions. 1. Coat the threads with sealer GM P/N 9985253 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2304 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor harness connector to the ECT sensor. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Temperature sticks can be used to determine a thermostat's operating range, by rubbing 87°C (188°F) and 97°C (206°F) sticks on the thermostat housing. Use a J 24731 Tempil Stick in order to find the opening and the closing temperatures of the coolant thermostat. J 24731-188 tempil stick melts at 87°C (188°F). The thermostat should begin to open. J 24731-206 tempil stick melts at 97°C (206°F). The thermostat should be fully open Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2308 Thermostat: Service and Repair Thermostat Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Drain the coolant to a level below the thermostat. 2. Remove the air cleaner assembly. 3. Disconnect the ground lead from the coolant outlet. 4. Remove the bolt/stud and the bolt on the coolant outlet. 5. Remove the coolant outlet. 6. Remove the thermostat. 7. Clean all of the parts and the sealing surfaces. Installation Procedure 1. Install the thermostat. 2. Install the coolant outlet. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt and the bolt/stud. ^ Tighten the bolt and the bolt/stud to 25 Nm (18 ft. lbs.). 4. Install the ground lead to the bolt/stud. 5. Install the air cleaner assembly. 6. Refill the coolant. 7. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Install the four bolts retaining the coolant pump. Water Pump Bolt ................................................................................................................................. ................................................. 45 Nm (33 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2312 Water Pump: Service and Repair Water Pump Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Drain the coolant from the radiator. 2. Remove the air cleaner assembly. 3. Remove the Mass Air Flow (MAF) sensor. 4. Remove the upper fan shroud. 5. Remove the drive belt. 6. Remove the fan and fan blade clutch assembly. 7. Remove the coolant pump pulley bolts and the pulley. 8. Disconnect the coolant bypass hose and clamps. 9. Disconnect the radiator outlet hose from the coolant pump. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2313 10. Remove the four coolant pump bolts. 11. Remove the coolant pump. 12. Remove the gaskets. Important: Make sure all of the gasket mating surfaces are free of burrs or other imperfections. 13. Inspect all of the parts. Replace the parts as necessary. Installation Procedure 1. Install the coolant pump gaskets. 2. Install the coolant pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the four bolts retaining the coolant pump. ^ Tighten the bolts to 45 Nm (33 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2314 4. Connect the coolant bypass hose and clamps. 5. Connect the radiator outlet hose to the coolant pump. 6. Install the coolant pump pulley and the bolts. ^ Tighten the coolant pump pulley bolts to 25 Nm (18 ft. lbs.). 7. Install the fan and fan blade clutch assembly. 8. Install the drive belt. 9. Install the upper fan shroud and the bolts. 10. Install the Mass Air Flow (MAP) sensor. 11. Install the air cleaner assembly. 12. Refill the radiator with coolant. 13. Start engine. After engine reaches normal operating temperature, check for coolant leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolt/Stud First Pass ............................................................................................................................................. .................................................. 15 Nm (11 ft. lbs.) Final Pass ........................................................... ................................................................................................................................... 30 Nm (22 ft. lbs.) Upper Radiator Hose Support Bracket Nut to Exhaust Manifold Stud ..................................................................................................... 36 Nm (27 ft. lbs.) Exhaust Manifold Surface Flatness-Flange to Flange ................................................................................................................................................... 0.25 mm (0.010 inch) Surface Flatness-Individual Flange .................................................................................................................................................. 0.05 mm (0.002 inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left Removal Procedure 1. Remove the engine cover. 2. Disconnect the Engine Coolant Temperature (ECT) sensor. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the left front tire. 5. Remove the left fender wheelhouse extension. 6. Remove the catalytic converter assembly. 7. Remove the spark plug wires from the spark plugs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2321 8. Remove the spark plug wire support bolts. 9. Remove the spark plug wire support with the spark plug wires. 10. Remove the front 4 exhaust manifold bolts through the wheelhouse. 11. Remove the 2 rear exhaust manifold bolts through the engine cover opening. 12. Remove the exhaust manifold, gaskets and the spark plug wire shields from underneath the vehicle. 13. Clean all gasket surfaces. Installation Procedure Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place. 1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold. 2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets. 3. Install the exhaust manifold. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2322 - Tighten the 2 rear exhaust manifold bolts through the engine cover opening. - Tighten the front 4 exhaust manifold bolts through the wheelhouse. 4. Install the spark plug wires to the spark plugs. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the spark plug wire support and bolts. Tighten the spark plug wire support bolts to 12 Nm (106 inch lbs.). 6. Install the catalytic converter assembly. 7. Install the fender wheelhouse extension. 8. Install the left front tire. 9. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2323 10. Connect the ECT sensor electrical connector. 11. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2324 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement - Right Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the right front tire. 3. Remove the right fender wheelhouse extension. 4. Disconnect the spark plug wires from the spark plugs. 5. Remove the catalytic converter assembly. 6. Remove the exhaust manifold bolts through the wheelhouse. 7. Remove the exhaust manifold with the exhaust manifold gaskets and the spark plug wire shields from the engine. 8. Clean all gasket surfaces. Installation Procedure Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place. 1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2325 2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets. 3. Install the exhaust manifold. 4. Install the catalytic converter assembly. 5. Install the spark plug wires. 6. Install the fender wheelhouse extension. 7. Install the front tire. 8. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe Exhaust Pipe-to-Manifold Nuts Torque ................................................................................................................................................. ........................................... 53 Nm (39 ft. lbs.) Exhaust Pipe-to-Manifold Studs Torque ................................................................................................................................................. ........................................... 15 Nm (11 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Muffler Hanger Hanger-to-Frame Nuts Torque ................................................................................................................................................. ........................................... 45 Nm (33 ft. lbs.) Hanger-to-Transfer Case Bolts (A4WD) Torque ................................................................................................................................................. ........................................... 55 Nm (41 ft. lbs.) Hanger-to-Transmission Bolts (RWD) Torque ................................................................................................................................................. ........................................... 45 Nm (33 ft. lbs.) Hanger-to-Frame Bolts Torque ................................................................................................................................................. ........................................... 25 Nm (18 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler Replacement Removal Procedure Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury. Caution: In order to avoid being burned, do not service the exhaust system while it is still hot Service the system when it is cool. An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the muffler assembly. 3. Remove the 3 nuts connecting the muffler assembly to the catalytic converter assembly. 4. To aid in the removal of the muffler assembly, lubricate the rubber hangers with rubber lubricant GM P/N 12345884. Remove the muffler assembly from the front hanger. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2335 5. Remove muffler assembly from the rear hanger. 6. Remove the muffler assembly from the tailpipe hanger. 7. Remove the muffler assembly from the vehicle. Installation Procedure When installing exhaust components, inspect the exhaust system for proper alignment. Misaligned components commonly cause rattles, noise and vibrations in the exhaust system. During system alignment, leave all of the bolts or nuts loose, until all of the parts are properly aligned. After properly aligning the parts, tighten the bolts or nuts from the front to the rear. In order to maintain the alignment of the exhaust system, replace any damaged exhaust system hangers, hanger brackets, and clamps. Important: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed. - Replace the tailpipe when replacing the muffler. - Always use new nuts when installing the exhaust pipe to the exhaust manifold. - Before installing the new nuts, clean the exhaust manifold stud threads with a wire brush. 1. To aid in the installation of the muffler assembly, lubricate the rubber hangers with rubber lubricant GM PIN 12345884. Install the muffler assembly into the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2336 2. Connect the muffler assembly to the tailpipe hanger. 3. Connect the muffler assembly to the rear hanger. 4. Connect muffler assembly to the front hanger. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2337 5. Install the 3 nuts to connect the muffler assembly to the catalytic converter assembly. Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2344 Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2345 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2346 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2347 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2348 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2351 Body Control Module C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2352 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2353 Body Control Module C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2354 Body Control Module C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2355 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module C3 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2356 Body Control Module C3 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 2357 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2360 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control.Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2361 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2362 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The Scan Tool 9. Perform the body control module programing. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2367 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2368 Engine Control Module: Locations Powertrain Control Module (PCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2369 Powertrain Control Module (PCM) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2372 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2373 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2374 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2375 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2376 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2377 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2378 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System Engine Control Module: Description and Operation Powertrain Control Module & the Theft Deterrent System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2381 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2382 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the symbols shown when commanded ON. The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTC's). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTC's when 40 consecutive warm-up cycles occur without a malfunction. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2383 DIAGNOSTIC TROUBLE CODES (DTC's) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTC's alert the driver via the MIL or a message. Other DTC's do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTC's are set. This data is stored in the Freeze Frame and/or Failure Records. The DTC's are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTC's and different actions taken when the DTC's set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTC's, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTC's only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTC's were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTC's will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTC's and type B DTC's (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTC's that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTC's will be listed in this category if the diagnostic has not run since DTC's were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2384 Engine Control Module: Description and Operation Distributor Ignition (DI) System The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2385 Engine Control Module: Service and Repair Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: - To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. Removal Procedure 1. Disconnect the PCM harness connectors (4). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2386 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). 3. Connect the PCM connectors (4) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure). See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2391 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2392 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2393 Ignition Control Module (ICM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2394 Ignition Control Module: Description and Operation The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2395 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2401 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2402 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2403 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2404 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2405 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2406 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2410 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2411 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2412 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2413 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2414 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2415 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2416 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2417 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2418 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2422 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2423 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Drain the coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Disconnect the electrical connector. 5. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Refer to Component Fastener Tightening Notice in Service Precautions. 1. Coat the threads with sealer GM P/N 9985253 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2424 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor harness connector to the ECT sensor. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 2433 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2439 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2440 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2441 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 2446 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2452 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 04-03-10-004 > May > 04 > Wheels - Wheel Fastener Torque Specification Update Wheel Fastener: All Technical Service Bulletins Wheels - Wheel Fastener Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 04-03-10-004 Date: May, 2004 SERVICE MANUAL UPDATE Subject: Revised Tire and Wheel Removal and Installation Fastener Tightening Specification Models: 2003 Chevrolet Astro Van 2003 GMC Safari Van This bulletin is being issued to revise the fastener tightening specification in the Tire and Wheel Removal and Installation procedure in the Tires and Wheels sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct tightening specification for the wheel nuts (Step 2 of Installation) is 190 N.m (140 lb ft). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 02-03-10-008 > Dec > 02 > Wheels/Tires Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2466 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2475 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2476 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2477 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2480 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2481 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2482 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2483 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 2487 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2491 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2492 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2496 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2497 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2498 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2499 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2500 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2504 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2505 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2506 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2507 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2511 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2512 MAP, Purge Solenoid, And Throttle Body Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2513 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2514 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2515 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2516 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2517 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J 41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 2521 1. Install the engine oil pressure gage sensor fitting, if removed. Tighten 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J 41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2525 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2526 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2527 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2530 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2531 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (4) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2532 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2533 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (1) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 2534 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2538 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2539 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2540 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2541 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2545 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2546 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2547 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2548 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2549 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Transmission Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 Vehicle Speed Sensor (VSS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 > Page 2555 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2556 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Tools Required ^ J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417. 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2561 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2562 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2563 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2564 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2565 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2566 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2570 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2571 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2572 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2573 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2578 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2579 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2580 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2581 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2582 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2583 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2584 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2585 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2586 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 2595 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2601 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2602 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2603 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 2608 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2614 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2615 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2616 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2617 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2618 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2619 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2622 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2623 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2624 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2625 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2629 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2630 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2631 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2632 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2638 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2639 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2640 Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2641 Steps 4-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2642 Step 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2643 Steps 9-12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2644 Steps 13-14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2645 Steps 15-18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2646 Steps 19-23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2659 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2665 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2666 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2672 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2673 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2677 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots 1/2 turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2686 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2687 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2693 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2694 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Page 2695 Distributor: Testing and Inspection DISTRIBUTOR INSPECTION 1. Remove the engine cover. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 2. Remove the 2 screws from the rotor. 3. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2698 4. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 5. Line up the square-cut hole in the vane wheel with the CMP sensor. 6. Remove the 2 screws that hold the camshaft position (CMP) sensor. 7. Discard the screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2699 8. Remove the CMP sensor. 9. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 10. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 11. Drive out the roll pin with a suitable punch. 12. Remove the driven gear from the distributor shaft. 13. Remove the round washer. 14. Remove the tang washer. 15. Remove the shim washer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2700 16. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Insert the sensor into the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2701 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2702 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2703 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2704 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. - Twist each spark plug wire 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2705 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2706 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2707 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2708 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 15. Install the engine cover. INSTALLATION PROCEDURE 2 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2709 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 2. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2710 3. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. 4. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 5. Install the distributor cap. 6. Install the new distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2711 Tighten Tighten the screws to 2.4 N.m (21 lb in). 7. Install the electrical connector to the distributor. 8. Install the spark plug wires to the distributor cap. 9. Install the ignition coil wire. Note the correct orientation of the wire boot. 10. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 11. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug: Electrical Specifications Spark Plug Wire Resistance................................................................................................................. ........................................................1,000 ohms per ft Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 2716 Spark Plug: Mechanical Specifications Spark Plug Gap 0.060 in. 1.52 mm Spark Plug Torque Used Heads 15 Nm 11 lb. ft. New Aluminum Heads 20 Nm 15 lb. ft. New Iron Heads 30 Nm 22 lb. ft. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2717 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ....................................................... AC Type 41-932 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2718 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2719 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2720 - Incorrect combustion - Reduced ignition system voltage output - Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2721 Spark Plug: Service and Repair REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.524 mm (0.060 in). 3. Hand start the spark plugs in the corresponding cylinders. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plugs. Tighten For used heads tighten the spark plugs to 15 N.m (11 lb ft). - For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). - For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 1. Install the spark plug wires. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2725 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml. (1 oz.) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2733 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2734 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2735 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2736 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2737 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2738 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2742 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2743 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2744 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2745 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2746 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2750 Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2751 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2752 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2753 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2754 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2757 Body Control Module C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2758 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2759 Body Control Module C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2760 Body Control Module C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2761 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module C3 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2762 Body Control Module C3 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 2763 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2766 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control.Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2767 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2768 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The Scan Tool 9. Perform the body control module programing. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2772 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2773 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2774 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2775 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2776 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2777 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2778 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2779 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2780 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2784 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2785 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Drain the coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Disconnect the electrical connector. 5. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Refer to Component Fastener Tightening Notice in Service Precautions. 1. Coat the threads with sealer GM P/N 9985253 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2786 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor harness connector to the ECT sensor. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set > Page 2795 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2801 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2802 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2803 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 2808 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2814 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2815 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 2816 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2817 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2818 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2819 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2822 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2823 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2824 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2825 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Timing Ring > Component Information > Service and Repair Crankshaft Position Timing Ring: Service and Repair Crankshaft Position (CKP) Reluctor Ring Replacement Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Installation Procedure Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face towards the engine front cover. 1. Install the crankshaft position sensor reluctor ring. 2. Install the engine front cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Splice Pack, Relay Block, DLC Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2832 Data Link Connector (DLC) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2837 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2838 Engine Control Module: Locations Powertrain Control Module (PCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2839 Powertrain Control Module (PCM) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2842 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2843 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2844 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2845 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2846 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2847 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 2848 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System Engine Control Module: Description and Operation Powertrain Control Module & the Theft Deterrent System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2851 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2852 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the symbols shown when commanded ON. The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTC's). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTC's when 40 consecutive warm-up cycles occur without a malfunction. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2853 DIAGNOSTIC TROUBLE CODES (DTC's) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTC's alert the driver via the MIL or a message. Other DTC's do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTC's are set. This data is stored in the Freeze Frame and/or Failure Records. The DTC's are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTC's and different actions taken when the DTC's set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTC's, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTC's only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTC's were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTC's will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTC's and type B DTC's (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTC's that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTC's will be listed in this category if the diagnostic has not run since DTC's were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 2854 Engine Control Module: Description and Operation Distributor Ignition (DI) System The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2855 Engine Control Module: Service and Repair Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: - To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. Removal Procedure 1. Disconnect the PCM harness connectors (4). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2856 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). 3. Connect the PCM connectors (4) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure). See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 2860 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2864 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2865 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams Idle Air Control (IAC) Valve Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2869 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2870 Steps 1-2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2871 Steps 3-5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2872 Steps 6-9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2873 Steps 10-11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2874 Steps 12-15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2875 Steps 16-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2876 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the harness connector from the idle air control (IAC) valve. 4. Remove the IAC valve attaching fasteners. 5. Remove the IAC valve assembly. NOTE: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2877 6. Remove the O-ring. CLEANING AND INSPECTION PROCEDURE 1. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage. - Use a carburetor cleaner and a parts cleaning brush in order to remove any carbon deposits. Follow the instructions on the container. - Do not use a cleaner that contains methyl ethyl ketone. MEK is an extremely strong solvent and not necessary for this type of deposit. - Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft. - If the air passage has heavy deposits, remove the throttle body for a complete cleaning. Refer to Throttle Body Assembly Replacement and to Throttle Body Cleaning Procedure. 2. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if damaged. INSTALLATION PROCEDURE 1. Measure the distance between tip of the IAC valve pintle and the mounting flange. If the distance is more than 28 mm (1.10 in), use finger pressure in order to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. IMPORTANT: If you are installing a new IAC valve, replace the valve with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. 2. Lubricate the IAC valve O-ring with clean engine oil. 3. Install the IAC valve assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2878 4. Install the attaching fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the IAC valve fasteners to 3 N.m (27 lb in). 5. Connect the IAC harness connector. 6. Install the engine cover. 7. Reset the IAC valve pintle position. IAC VALVE RESET PROCEDURE 1. Turn ON the ignition for 5 seconds, leaving the engine OFF. 2. Turn OFF the ignition for 10 seconds. 3. Start the engine. 4. Check for the proper idle speed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2916 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2917 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2918 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2919 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2920 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2945 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2959 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2960 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2961 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2962 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 Data Link Connector (DLC) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 Information Bus: Electrical Diagrams Data Link Connector Diagram Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2969 Information Bus: Description and Operation DATA LINK COMMUNICATIONS DATA LINK COMMUNICATIONS CIRCUIT DESCRIPTION AND OPERATION The Class 2 serial data link allows specified modules to transmit, receive, or exchange data: transfer case shift control module (TCSCM) - electronic brake control module (EBCM) - powertrain control module (PCM) - body control module (BCM) - instrument panel cluster (IPC) - driver information center (DIC) - inflatable restraint sensing and diagnostic module (SDM) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the class 2 serial data circuit about once every 2 seconds. When the module detects the class 2 serial data circuit shorted, the setting of all other class 2 serial communication DTCs is inhibited and a U1300, U1301, or a U1305 DTC will set. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - DATA LINK COMMUNICATIONS Begin the diagnosis of the data link communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2972 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications SYMPTOMS - DATA LINK COMMUNICATIONS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check for the subsystem exhibiting the symptoms. The subsystem diagnostic system check will identify where to begin diagnosis of the data link communication system. 2. Review the system operation in order to familiarize yourself with the system functions. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the vehicle systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS - The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. - When the class 2 serial data circuit: is shorted to ground - is shorted to voltage The following DTCs may set: U1300 - U1301 - U1305 TEST DESCRIPTION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2973 Steps 1-6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2974 Steps 7-9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2975 Steps 10-11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2976 Steps 12-14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2977 Steps 15-20 The numbers below refer to the step numbers on the diagnostic table. 2. A partial loss of communication in the class 2 serial data circuit uses a different procedure than a total loss of communication of the class 2 serial data circuit. 4. The following DTCs may be retrieved with a history status. These DTCs are not the cause of the present condition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2978 - U1300 - U1301 - U1305 6. A State of Health DTC with a history status may be present along with a U1000 or U1255 with a current status. This indicates that the malfunction occurred when the ignition was on. 10. Normal class 2 serial data communication cannot take place until the power mode master (PMM) module sends the appropriate power mode message. If the PMM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 12. Normal class 2 serial data communication cannot take place until the power mode master (PMM) module sends the appropriate power mode message. If the PMM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 17. If there are no current DTCs that begin with the letter "U", the communication concern has been repaired. 18. The communication concern may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Common signal ground at terminal 5. The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2979 Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2980 Step 4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2984 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2985 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2986 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2987 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the symbols shown when commanded ON. The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2994 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2995 MAP, Purge Solenoid, And Throttle Body Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2996 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2997 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2998 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2999 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3000 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J 41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3004 1. Install the engine oil pressure gage sensor fitting, if removed. Tighten 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J 41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3008 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3009 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3010 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3013 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3014 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (4) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3015 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3016 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (1) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3017 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3022 Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3023 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3024 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3025 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3026 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3029 Body Control Module C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3030 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3031 Body Control Module C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3032 Body Control Module C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3033 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module C3 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3034 Body Control Module C3 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 3035 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3038 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control.Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3039 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3040 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The Scan Tool 9. Perform the body control module programing. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3045 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3046 Engine Control Module: Locations Powertrain Control Module (PCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3047 Powertrain Control Module (PCM) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 3050 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 3051 Powertrain Control Module (PCM) C1 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 3052 Powertrain Control Module (PCM) C1 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 3053 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 3054 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 3055 Powertrain Control Module (PCM) C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module (PCM) C1 > Page 3056 Powertrain Control Module (PCM) C2 Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System Engine Control Module: Description and Operation Powertrain Control Module & the Theft Deterrent System POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 3059 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 3060 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the symbols shown when commanded ON. The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTC's). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTC's when 40 consecutive warm-up cycles occur without a malfunction. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 3061 DIAGNOSTIC TROUBLE CODES (DTC's) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTC's alert the driver via the MIL or a message. Other DTC's do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTC's are set. This data is stored in the Freeze Frame and/or Failure Records. The DTC's are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTC's and different actions taken when the DTC's set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTC's, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTC's only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTC's were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTC's will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTC's and type B DTC's (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTC's that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTC's will be listed in this category if the diagnostic has not run since DTC's were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module & the Theft Deterrent System > Page 3062 Engine Control Module: Description and Operation Distributor Ignition (DI) System The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3063 Engine Control Module: Service and Repair Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: - To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. Removal Procedure 1. Disconnect the PCM harness connectors (4). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3064 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). 3. Connect the PCM connectors (4) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure). See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3069 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3070 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3071 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3072 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3073 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3074 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3078 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3079 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3080 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3081 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3082 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3083 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3084 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3085 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3086 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3090 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3091 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Drain the coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System in Cooling System. 4. Disconnect the electrical connector. 5. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Refer to Component Fastener Tightening Notice in Service Precautions. 1. Coat the threads with sealer GM P/N 9985253 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3092 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor harness connector to the ECT sensor. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3101 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3107 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3108 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3109 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3114 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3120 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3121 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3122 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3123 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3124 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3125 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3128 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3129 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3130 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3131 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3135 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 3139 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 3140 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3144 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3145 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3146 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3147 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3148 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3152 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3153 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3154 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3155 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3159 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3160 MAP, Purge Solenoid, And Throttle Body Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3161 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3162 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3163 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3164 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3165 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J 41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3169 1. Install the engine oil pressure gage sensor fitting, if removed. Tighten 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J 41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Heated Oxygen Sensors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3173 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3174 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3175 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3178 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3179 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (4) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3180 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3181 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 2. Install the HO2S (1) using a J 39194-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3182 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3186 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3187 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3188 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3189 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3193 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3194 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3195 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3196 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3197 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Transmission Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 Vehicle Speed Sensor (VSS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 > Page 3203 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3204 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Tools Required ^ J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417. 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3208 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3209 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3210 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3211 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3215 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3216 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3217 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3218 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3219 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Transmission Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 Vehicle Speed Sensor (VSS) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > VSS 12162194 > Page 3225 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3226 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Tools Required ^ J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417. 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine cover. 2. Remove the engine wiring harness bracket from the stud. 3. Disconnect the evaporative emissions (EVAP) canister purge pipe. 4. Disconnect the EVAP canister purge valve harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 3232 5. Remove the EVAP canister purge valve mounting nuts. EVAP Purge Valve 6. Remove the EVAP canister purge valve from the intake manifold. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 3233 EVAP Purge Valve 1. Install the EVAP canister purge valve to the intake manifold. 2. Install the EVAP canister purge valve mounting nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Connect the EVAP canister purge valve harness connector. 4. Connect the EVAP canister purge pipe. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 3234 5. Install the engine wiring harness bracket to the stud. Tighten Tighten the bracket nut to 8 N.m (71 lb in). 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3238 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3239 MAP, Purge Solenoid, And Throttle Body Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3240 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3241 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3242 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3243 Evaporator Emission (EVAP) Canister Purge Solenoid Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3244 Canister Purge Solenoid: Description and Operation EVAP PURGE SOLENOID The EVAP purge solenoid controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid opens when commanded ON by the control module. This normally closed solenoid is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The solenoid will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations Canister Vent Valve: Locations Evaporative Emission (EVAP) Canister Vent Solenoid Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3249 Undercarriage Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3250 Evaporator Emission (EVAP) Canister Vent Solenoid Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3251 Canister Vent Valve: Description and Operation EVAP VENT SOLENOID The EVAP vent solenoid controls fresh airflow into the EVAP canister. The solenoid is normally open. The control module commands the solenoid ON, closing the solenoid during some EVAP tests, allowing the system to be tested for leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3252 Canister Vent Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER VENT VALVE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the evaporative emission (EVAP) canister vent valve bracket bolt (5) from the vent valve bracket (1). 3. Disconnect the vent valve harness connector (4) from the vent valve (6). 4. Disconnect the vent pipe (3) from the vent valve (6). 5. Remove the vent valve. 6. Remove the vent valve from the bracket. INSTALLATION PROCEDURE 1. Install the vent valve on the bracket. 2. Install the EVAP canister vent pipe (3) on the EVAP canister vent valve (6). 3. Connect the EVAP canister vent valve harness connector (4) to the EVAP canister vent valve. 4. Install the EVAP canister vent valve bracket (1) and the vent valve bracket bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining bolt to 10 N.m (89 lb in). 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement - Engine Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Engine REMOVAL PROCEDURE IMPORTANT: When replacing the evaporative emission (EVAP) pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. 1. Remove the engine cover. 2. Clean the pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the EVAP system. 3. Disconnect the engine compartment EVAP pipe at the EVAP canister purge valve. 4. Disconnect the engine compartment EVAP pipe (1) at the chassis EVAP pipe (2). 5. Remove the EVAP pipe from the engine. 6. Cap the EVAP canister purge valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement - Engine > Page 3257 1. Remove the caps from the EVAP canister purge valve and the chassis EVAP pipe. 2. Install the EVAP pipe on the engine. 3. Connect the engine compartment EVAP pipe (1) to the chassis EVAP pipe (2). 4. Connect the engine compartment EVAP pipe at the EVAP canister purge valve. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement - Engine > Page 3258 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the EVAP vapor pipe (5) from the EVAP canister (1). 3. Disconnect the EVAP vapor pipe from the fill limiter vent valve (2). 4. Remove the EVAP vapor pipe. INSTALLATION PROCEDURE 1. Connect the EVAP vapor pipe (5) to the fill limiter vent valve (2). 2. Connect the EVAP vapor pipe to the EVAP canister (1). 3. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement - Engine > Page 3259 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Chassis/Canister REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the rear chassis EVAP purge pipe (3) from the EVAP canister (1). 3. Remove the rear chassis EVAP purge pipe. INSTALLATION PROCEDURE 1. Connect the rear chassis EVAP purge pipe (3) to the EVAP canister (1). 2. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement - Engine > Page 3260 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Engine/Chassis REMOVAL PROCEDURE 1. Remove the engine cover. 2. Clean all the pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination. 3. Disconnect the chassis EVAP pipe from the engine compartment EVAP purge pipe (9). 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the fuel/EVAP pipes bundle retainer mounting stud (7) from the cylinder head. 6. Remove the fuel/EVAP pipes bundle retainer mounting stud (6) from the transmission. 7. Remove the fuel/EVAP pipes bundle retainer mounting fastener (5) from the crossrail. 8. Disconnect the front chassis EVAP purge pipe from the rear chassis EVAP purge pipe (4). 9. Note the position of the EVAP pipe for aid in installation. 10. Remove the EVAP pipe from the retaining clips. 11. Remove the EVAP pipe. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement - Engine > Page 3261 1. Connect the front chassis EVAP pipe to the rear chassis EVAP purge pipe (4). IMPORTANT: When replacing the fuel/EVAP pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The replacement pipes must have the same type of fittings as the original pipes in order to ensure the integrity of the connection. - Do not use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M specification or its equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required. 1. Install the EVAP pipe into the transmission bracket retainer. 2. Install the mounting stud (6). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the mounting stud to 33 N.m (24 lb ft). 3. Install the EVAP pipe into the cylinder head retainer. 4. Install the mounting stud (7). Tighten Tighten the mounting stud to 33 N.m (24 lb ft). 5. Install the EVAP pipe into the crossrail retainer. 6. Install the mounting bolt (5) to the crossrail. Tighten Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement - Engine > Page 3262 Tighten the mounting bolt to 11 N.m (97 lb in). 7. Lower the vehicle. 8. Connect the chassis EVAP pipe to the engine compartment EVAP pipe (9). 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid and the EVAP canister. The service port is identified by a green colored cap. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3271 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3272 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3273 Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3274 Steps 4-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3275 Step 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3276 Steps 9-12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3277 Steps 13-14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3278 Steps 15-18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3279 Steps 19-23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3284 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3285 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair ACCELERATOR CONTROLS PEDAL REPLACEMENT REMOVAL PROCEDURE 1. Lift upward on the accelerator pedal (3) to relieve tension on the cable (2). 2. Remove the retainer (1) from the pedal lever (4) hole. 3. Remove cable (2) from the slot in the pedal lever (4). 4. Remove the accelerator pedal mounting fasteners. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE IMPORTANT: The accelerator cable is not to be kinked or damaged in any way during installation. Ensure that the mounting surface between the accelerator pedal assembly and the dash panel is free of insulation. The carpet and padding in the pedal area must be positioned to lay flat and be free of wrinkles and bunches. Wire, hoses, cables, and other flexible components should not be within 13 mm (0.52 in) of the cable or lever, at any point in their travel. 1. Place the accelerator pedal assembly on the mounting surface. 2. Install the three mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the pedal assembly to 5 N.m (44 lb in). 3. Lift upward on the accelerator pedal (3). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Page 3292 4. Insert the cable (2) through the pedal lever slot. 5. Press the retainer (1) into the lever hole until fully seated. 6. Check the pedal (3) for free movement by pressing down on the pedal. IMPORTANT: The pedal must operate freely without binding through the full range of pedal movement. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3302 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3308 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3309 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3313 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3314 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3315 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3316 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3317 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3318 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3323 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3324 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3325 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3326 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3327 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3328 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3329 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3330 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and you hear heavy knocking, your engine needs service. ADDITIVES To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. Gasoline containing oxygenates, such as ethers and ethanol, and reformulated gasoline may be available in your area to contribute to clean air. General Motors recommends that you use these gasoline, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Don't use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage wouldn't be covered under your warranty. Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasoline. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California specifications. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool Fuel: Testing and Inspection With Special Tool TEST DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Alcohol concentrations of 10 percent or more in the fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. TEST PROCEDURE 1. Turn ON the J 44175 Fuel Composition Tester. 2. Verify the fuel composition tester is operational by measuring the AC frequency output with a DMM. Refer to Measuring Frequency in Diagnostic Aids. A frequency without a fuel sample in the test cell indicates that the tester is working correctly. 3. Install the fuel pressure gage. 4. Close the bleed valve on the fuel pressure gage. IMPORTANT: Bleed the fuel pressure gage a few times in order to obtain an accurate fuel sample from the vehicle being tested. 5. Place the bleed hose (1) of the fuel pressure gage into the 100 ml beaker (2). 6. Command the fuel pump relay ON with a scan tool. 7. Slowly open the bleed valve on the fuel pressure gage, until an adequate fuel sample is obtained. 8. If water appears in the fuel sample, clean the fuel system and replace the fuel in the vehicle. Refer to Fuel System Cleaning. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool > Page 3333 9. Pour the fuel sample from the beaker (1) into the J 44175 , until the level of the fuel is at the top of each fuel test port (2). IMPORTANT: DO NOT allow any substances other than gasoline, ethanol/gasoline blends, air, or acetone into the test ports of the fuel composition tester. Contaminants in the J 44175 could result in misdiagnosis. 10. Observe the diagnostic LEDs on the fuel composition tester. If the red fuel diagnostic LED is illuminated, a fuel contamination condition exists. Refer to Fuel System Cleaning. 11. Measure the output frequency of the fuel composition tester. Fuel Composition Test Examples 12. Subtract 50 from the reading on the DMM to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the table. 13. If the fuel sample contains more than 10 percent ethanol, add gasoline to the fuel tank or replace the fuel in the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool > Page 3334 Fuel: Testing and Inspection Without Special Tool TEST DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Alcohol concentrations of 10 percent or more in the fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. ALCOHOL IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. PARTICULATE CONTAMINANTS IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the container on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Refer to Fuel System Cleaning. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Page 3335 Fuel: Service and Repair FUEL SYSTEM CLEANING REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel sender assembly. 3. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump. 4. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet. 5. Flush the fuel tank with hot water. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state and federal laws and regulations. 6. Pour the water out of the fuel sender assembly opening. 7. Rock the fuel tank to be sure that the removal of water from tank is complete. 8. Inspect the in-line fuel filter for contamination. 9. Replace the fuel filter if the filter is plugged. 10. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow. IMPORTANT: Only use oil free compressed air to blow out the fuel pipes. 11. Install the fuel sender assembly with a new seal into the fuel tank. 12. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over-tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3344 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3345 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 3350 Fuel Injector: Diagrams Central Sequential Fuel Injection (CSFI) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 3351 Central Sequential Fuel Injection (CSFI) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 3352 Fuel Injector: Description and Operation The Multec 2 fuel injector assembly is a solenoid device controlled by the control module that meters pressurized fuel to a single engine cylinder. The control module energizes the high-impedance, 12 ohms, injector solenoid to open a normally closed ball valve. This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has four machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. TEST Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3355 Steps 4-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3356 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool SYSTEM DESCRIPTION Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump relay. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3357 Steps 4-5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3358 Step 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3359 Steps 7-8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3360 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 SYSTEM DESCRIPTION Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump relay. The scan tool is then used to pulse each injector for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3361 Steps 4-5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3362 Step 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3363 Steps 7-8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3364 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS - Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may help isolate an intermittent condition. - Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics - For an intermittent condition, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3365 Steps 1-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3366 Fuel Injector: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the upper intake manifold assembly. 3. Remove the fuel meter body assembly (1). 4. Remove the injector assembly retainer (4) and the injector retainer lock nuts (2). 5. While pulling the injector tube downward, push with a small tip punch down between the injector terminals until the injector (3) is removed. NOTE: Use care in removing the fuel injectors to prevent damage to the electrical connector terminals. The fuel injector is serviced as a complete assembly only. Also since the injectors are electrical components, these injectors should not be immersed in any type of liquid solvent or cleaner as damage may occur. Fuel injector cleaning is not recommended. INSTALLATION PROCEDURE 1. Lubricate the O-ring seals with engine oil on the new fuel injector assembly (3). IMPORTANT: Each injector is calibrated for a specific flow rate. Order the correct injector for the application being serviced when replacing the fuel injectors. 2. Install the fuel injector assembly (3) into the fuel meter body (1). 3. Install the injector assembly retainer (4) and the injector retainer lock nuts (2). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3367 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the injector retainer lock nuts to 3 N.m (27 lb in). 4. Install the fuel meter body assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) TOOLS REQUIRED J 37088-A Fuel Line Disconnect Tool Set REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting. 3. Blow dirt out of the fitting using compressed air. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. 5. Pull the connection apart. 6. Using a clean shop towel, wipe off the male pipe end. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 3373 1. Apply a few drops of clean engine oil to the male pipe end. CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the fitting together to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the fitting to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 3374 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. 2. Using compressed air, blow any dirt out of the quick-connect fitting. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 3. Squeeze the plastic retainer release tabs. 4. Pull the connection apart. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 3375 1. Apply a few drops of clean engine oil to the male fuel pipe end. CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Meter Body > Component Information > Description and Operation Fuel Meter Body: Description and Operation The fuel meter body assembly (1) attaches to the lower intake manifold. The fuel meter body assembly performs the following functions: - Distributes fuel evenly to the injectors (3) - Integrates the fuel pressure regulator (6) into the fuel metering system Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Meter Body > Component Information > Description and Operation > Page 3379 Fuel Meter Body: Service and Repair REMOVAL PROCEDURE An 8-digit part identification number is on a mylar label affixed to the fuel meter body assembly. Refer to this number if servicing or part replacement is required. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the upper intake manifold assembly. 3. Before removal, clean the fuel meter body assembly with a spray type engine cleaner, GM X-30A, if necessary. Follow the package instructions. Do not soak fuel meter body assemblies in liquid cleaning solvent. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 4. Squeeze the injector locking tabs together while lifting the injector out of the casting socket. NOTE: Cover the injector sockets in order to prevent dirt and other contaminants from entering the open fuel passages. IMPORTANT: When disconnecting the injectors, remember the sequence in order to ensure correct injector placement to each cylinder. 5. Remove the fuel meter body from the bracket by releasing the lock tabs on the bracket. INSTALLATION PROCEDURE 1. Install the MFI fuel meter body into the bracket on the lower intake manifold. Place all of the fuel tubes in a forward position. Route the number 3 fuel tube behind the numbers 1 and 5 fuel tubes. 2. Insert the 6 injectors in the following sequence: 2.1. Insert #3 injector into the #3 injector hole. 2.2. Insert #5 injector into the #5 injector hole. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Meter Body > Component Information > Description and Operation > Page 3380 2.3. Insert #1 injector into the #1 injector hole. 2.4. Insert #2 injector into the #2 injector hole. 2.5. Insert #4 injector into the #4 injector hole. 2.6. Insert #6 injector into the #6 injector hole. CAUTION: Verify that the injectors are firmly seated and locked in their casting sockets, in order to reduce the risk of fire and personal injury. An unlocked or a loose injector could work loose from its socket and produce a fuel leak. If an injector is loose, replace the retainer. IMPORTANT: The fuel meter body assembly and the lower intake are numbered to indicate correct injector order. Ensure that the electrical connectors on the injectors do not interfere with each other and point towards the center of the intake manifold. Rotate the electrical connectors inboard, if necessary. 3. Install the upper intake manifold assembly. 4. Connect the negative battery cable. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition. 5.4. Inspect for fuel leaks. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Assembly The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. The fuel pressure regulator compensates for engine load by increasing fuel pressure as the engine vacuum drops. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3384 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Computers and Control Systems. 2. Remove the upper intake manifold assembly. 3. Remove the fuel pressure regulator retainer clip (5). 4. Pull and twist the fuel pressure regulator (6) in order to remove the fuel pressure regulator from the fuel pressure regulator housing using a shop towel to catch any spilled fuel. 5. Remove the regulator seal lower O-ring (3). 6. Remove the regulator assembly filter (2). 7. Remove the regulator seal upper O-ring (1). 8. Remove the regulator seal backup ring (7). 9. Discard the O-rings. INSTALLATION PROCEDURE IMPORTANT: If the fuel pressure regulator is to be reinstalled, inspect the filter screen for contamination. If the filter screen is contaminated, replace the regulator. 1. Lubricate the new O-rings with clean engine oil. 2. Install the regulator seal backup ring (7). 3. Install the regulator seal upper O-ring (1). 4. Install the regulator assembly filter (2). 5. Install the regulator seal lower O-ring (3). 6. Assemble the regulator (6) with the vacuum tube pointing down into the regulator retainer clip. 7. Install the fuel pressure regulator retainer clip (5). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3385 8. Install the upper manifold assembly. 9. Connect the negative battery cable. 10. Inspect for leaks. 10.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition, with the engine OFF. 10.4. Inspect for fuel leaks. 11. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. 2. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: - The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3391 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3392 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3393 Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3394 Steps 4-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3395 Step 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3396 Steps 9-12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3397 Steps 13-14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3398 Steps 15-18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3399 Steps 19-23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 3403 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Note the position of the fuel strainer (2) on the fuel sender. 3. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand. 4. Pull the strainer off the fuel sender. Discard the strainer after inspection. 5. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank. INSTALLATION PROCEDURE 1. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated. 2. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation FUEL FEED AND RETURN PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel injection system. The fuel return pipe carries fuel from the fuel injection system back to the fuel tank. The fuel pipes consist of 2 sections: - The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon. - The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel injection system. The chassis fuel pipes are constructed of steel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation NYLON FUEL PIPES CAUTION: In order to reduce the risk of fire and personal injury observe the following items: - Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes - Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used: - 9.53 mm (3/8 in) ID for the fuel feed - 7.94 mm (5/16 in) ID for the fuel return - 12.7 mm (1/2 in) ID for the vent Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. FUEL PIPE O-RINGS O-rings seal the threaded connections in the fuel system. The fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the air cleaner outlet resonator. 3. Disconnect the left bank spark plug wires from the distributor. 4. Disconnect the fuel pipes at the rear of the intake manifold. 5. Remove the injector fuel inlet and outlet pipe retainer nuts. 6. Remove the injector fuel inlet and the outlet pipe retainer. 7. Remove the rear fuel pipe bracket retaining bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3412 8. Pull straight up on the fuel pipes in order to remove the fuel pipes from the fuel meter body. 9. Remove the O-ring seals from both ends of the fuel feed and return pipes. 10. Discard the O-ring seals. INSTALLATION PROCEDURE 1. Assemble the new O-rings into the inlet and outlet of the fuel meter body. 2. Apply a few drops of clean engine oil to the male tube ends. CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. 3. Install the fuel feed and return pipes to the fuel meter body. 4. Install the fuel pipe retainer and the attaching nuts. Once installed, pull on both ends of each connection in order to make sure they are secure. 5. Install the rear fuel pipe bracket retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3413 Tighten 1. Tighten the rear fuel pipe bracket bolt to 6 N.m (53 lb in). 2. Tighten the fuel pipe retainer nuts to 3 N.m (27 lb in). 3. Install the new O-ring seals on the engine fuel feed and the return pipes. 4. Connect the fuel feed and return pipes to the engine fuel pipes. Tighten Tighten the fuel pipe fittings to 30 N.m (22 lb ft). 5. Connect the negative battery cable. 6. Inspect for fuel leaks. 6.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Connect the left bank spark plug wires to the distributor. 8. Install the air cleaner outlet resonator. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3414 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Front) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel system. 3. Disconnect the fuel feed and return pipes (8) from the engine compartment fuel pipes. 4. Cap the engine compartment fuel pipes. 5. Raise the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipes retainer mounting stud (7) from the cylinder head. 7. Remove the fuel pipes retainer mounting stud (6) from the transmission. 8. Remove the fuel pipes retainer mounting fastener (5) from the crossrail. 9. Disconnect the fuel return pipe (2) at the coupler (3). 10. Disconnect the fuel feed pipe at the fuel filter outlet. 11. Cap the rear fuel pipes. 12. Note the position of the fuel pipes for aid in installation. 13. Remove the fuel pipes from the retaining clips. 14. Remove the fuel pipes. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3415 1. Remove the caps from the rear fuel pipes. IMPORTANT: When replacing the fuel pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The replacement pipes must have the same type of fittings as the original pipes in order to ensure the integrity of the connection. - Do not use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M specification or its equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required. 1. Connect the chassis fuel feed pipe at the fuel filter outlet. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fuel feed pipe fitting to 30 N.m (22 lb ft). 2. Connect the fuel return pipe (2) at the coupler (3). Tighten Tighten the return pipe fitting to 27 N.m (20 lb ft). 3. Install the fuel pipes into the transmission bracket retainer. 4. Install the mounting stud (6). Tighten Tighten the mounting stud to 33 N.m (24 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3416 5. Install the fuel pipes into the cylinder head retainer. 6. Install the mounting stud (7). Tighten Tighten the mounting stud to 33 N.m (24 lb ft). 7. Install the fuel pipes into the crossrail retainer. 8. Install the mounting bolt (5) to the crossrail. Tighten Tighten the mounting bolt to 11 N.m (97 lb in). 9. Lower the vehicle. 10. Remove the caps from the engine compartment fuel pipes. 11. Connect the fuel feed and return pipes (8) to the engine compartment fuel pipes. Ensure the O-rings are in place. Tighten Tighten the fuel feed and return pipe fittings to 30 N.m (22 lb ft). 12. Connect the negative battery cable. 13. Inspect for leaks. 13.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 13.2. Turn OFF the ignition for 10 seconds. 13.3. Turn ON the ignition, with the engine OFF. 13.4. Inspect for fuel leaks. 14. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3417 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Rear) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the front fuel pipes (3) from the rear chassis pipes (1). 3. Drain gasoline into an approved container. 4. Disconnect the fuel feed pipe (1) from the fuel filter. 5. Discard the O-ring. 6. Disconnect the fuel return pipe (2) from the coupler (3). 7. Discard the O-ring. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3418 8. Disconnect the fuel return (5) and the fuel feed (2) pipes from the fuel tank pipes (1). 9. Release the fuel pipe grommet (4) from the crossrail. 10. Remove the fuel pipe retainer (3) from the crossrail. 11. Release the fuel pipes from the retainer and the grommet. INSTALLATION PROCEDURE 1. Install the new O-rings on the engine fuel feed and return pipes. CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. 2. Position the fuel pipes into the crossrail retainer and the crossrail grommet. 3. Position the new fuel pipes through the crossrails in the original location. 4. Loosely assemble the fuel feed pipe (1) to the fuel filter. 5. Loosely assemble the fuel return pipe (2) to the coupler (3). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3419 6. Install the fuel pipe grommet (4) into the crossrail. Lubricate the grommet to aid in the installation. 7. Install the fuel pipe retainer to the crossrail. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fuel pipe crossrail retainer to 11 N.m (97 lb in). - Tighten the fuel feed pipe to fuel filter fitting to 27 N.m (20 lb ft) using a back-up wrench. - Tighten the fuel return pipe to coupler fitting to 27 N.m (20 lb ft) using a back-up wrench. 1. Apply a few drops of clean engine oil to the rear male connector pipe ends. 2. Connect the fuel return (5) and the fuel feed (2) pipes to the fuel tank pipes (1). 3. Connect the negative battery cable. 4. Inspect for fuel leaks. 4.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 4.2. Turn OFF the ignition for 10 seconds. 4.3. Turn ON the ignition, with the engine OFF. 4.4. Inspect for fuel leaks. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 3420 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel pipes (1) from the fuel sender (2). INSTALLATION PROCEDURE 1. Install fuel pipes (1) to the fuel sender (2). CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. 2. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation Fuel Filler Hose: Description and Operation FUEL FILL PIPE The fuel fill pipe has a built-in restrictor in order to prevent refueling with leaded fuel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement Fuel Filler Hose: Service and Repair Filler Tube Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the fuel tank to a level below that of the fuel tank filler tube. Refer to Fuel Tank Draining Procedure. 3. Remove the fuel filler tube to the fuel filler pocket screws (1). 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Wipe the fuel filler tube connection at the fuel tank with a clean cloth and then disconnect the fuel filler tube clamp (3). 6. Remove the fuel fill tube attaching screw (2) and the fuel filler tube. INSTALLATION PROCEDURE 1. Install the fuel filler tube into the fuel tank. 2. Install the fuel filler tube attaching screw (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the attaching screw to 11.5 N.m (102 lb in). 3. Connect the fuel filler tube hose and clamp (3). Tighten Tighten the fuel fill hose clamp to 3 N.m (27 lb in). 4. Install the fuel filler tube screws at the fuel filler pocket. Tighten Tighten the fuel filler tube screws to 1.9 N.m (17 lb in). 5. Connect the negative battery cable. 6. Refill the fuel tank. 7. Inspect for fuel leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 3427 Fuel Filler Hose: Service and Repair Fuel Filler Hose Replacement REMOVAL PROCEDURE 1. Remove the fuel filler tube. 2. Disconnect the fuel fill hose from the fuel fill tube. 3. Remove the fuel fill hose and the hose clamps (3). 4. Cap the fuel tank opening. INSTALLATION PROCEDURE 1. Uncap the fuel tank opening. 2. Install the fuel fill hose and the hose clamps (3) on to the filler tube. 3. Install the fuel filler tube. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 3431 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 3432 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Tank Unit: Diagrams Fuel Pump And Sender Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3436 Fuel Pump And Sender Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3437 Fuel Tank Unit: Description and Operation FUEL SENDER ASSEMBLY Fuel Sender Assembly The fuel sender assembly consists of the following major components: - The fuel level sensor (6) - The fuel tank pressure (FTP) sensor (1) - The fuel pump module (2) - The fuel strainer (3) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3438 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39765 Fuel Sender Locknut Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel sender electrical connectors. NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 3. Disconnect the fuel and EVAP pipes from the fuel sender. 4. Remove the fuel sender assembly retaining ring using the J 39765. 5. Remove the fuel sender assembly and the seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 6. Clean the fuel sender sealing surfaces. INSTALLATION PROCEDURE 1. Install the new seal on the fuel tank. CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3439 2. Install the fuel sender assembly into the fuel tank. IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm. 3. Install the fuel sender assembly retaining ring using the J 39765. 4. Connect the fuel and EVAP pipes to the fuel sender. 5. Connect the fuel sender electrical connectors. 6. Install the fuel tank. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams Idle Air Control (IAC) Valve Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3443 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3444 Steps 1-2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3445 Steps 3-5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3446 Steps 6-9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3447 Steps 10-11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3448 Steps 12-15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3449 Steps 16-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3450 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the harness connector from the idle air control (IAC) valve. 4. Remove the IAC valve attaching fasteners. 5. Remove the IAC valve assembly. NOTE: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3451 6. Remove the O-ring. CLEANING AND INSPECTION PROCEDURE 1. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage. - Use a carburetor cleaner and a parts cleaning brush in order to remove any carbon deposits. Follow the instructions on the container. - Do not use a cleaner that contains methyl ethyl ketone. MEK is an extremely strong solvent and not necessary for this type of deposit. - Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft. - If the air passage has heavy deposits, remove the throttle body for a complete cleaning. Refer to Throttle Body Assembly Replacement and to Throttle Body Cleaning Procedure. 2. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if damaged. INSTALLATION PROCEDURE 1. Measure the distance between tip of the IAC valve pintle and the mounting flange. If the distance is more than 28 mm (1.10 in), use finger pressure in order to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. IMPORTANT: If you are installing a new IAC valve, replace the valve with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. 2. Lubricate the IAC valve O-ring with clean engine oil. 3. Install the IAC valve assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3452 4. Install the attaching fasteners. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the IAC valve fasteners to 3 N.m (27 lb in). 5. Connect the IAC harness connector. 6. Install the engine cover. 7. Reset the IAC valve pintle position. IAC VALVE RESET PROCEDURE 1. Turn ON the ignition for 5 seconds, leaving the engine OFF. 2. Turn OFF the ignition for 10 seconds. 3. Start the engine. 4. Check for the proper idle speed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair AIR CLEANER OUTLET RESONATOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Remove the air cleaner outlet retaining nut (1). 4. Remove the air cleaner outlet duct (2) from the throttle body assembly. 5. Loosen the air cleaner outlet duct from the MAF/IAT sensor. 6. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair > Page 3456 1. Install the air cleaner outlet duct to the MAF/IAT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Install the air cleaner outlet duct (2) on the throttle body assembly. 3. Tighten the retaining nut (1). Tighten Tighten the nut 2 N.m (18 lb in). 4. Install the engine cover. 5. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3461 MAF, IAT, And Air Cleaner Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3462 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3463 Mass Air Flow (MAF) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3464 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. NOTE: Handle the MAF sensor carefully. - Do not drop the MAF sensor in order to prevent damage to the MAF sensor. - Do not damage the screen located on the air inlet end of the MAF. - Do not touch the sensing elements. - Do not allow solvents and lubricants to come in contact with the sensing elements. - Use a small amount of a soap based solution in order to aid in the installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3465 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3466 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3470 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3471 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3472 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3473 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement Throttle Body: Service and Repair Throttle Body Assembly Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the air cleaner outlet resonator. 4. Remove the air cleaner outlet resonator adapter stud. 5. Remove the cruise control cable. 6. Remove the accelerator cable. 7. Remove the stud and nuts retaining the accelerator control cable bracket and position bracket aside. 8. Disconnect the (IAC) valve harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3478 9. Disconnect the (TP) sensor harness connector. 10. Remove the throttle body retaining studs. 11. Remove the throttle body assembly. 12. Discard the throttle body seal. INSTALLATION PROCEDURE 1. Clean the gasket surface on the intake manifold. CAUTION: Refer to Safety Glasses Caution in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3479 2. Install the throttle body assembly with a new seal. 3. Install the throttle body assembly retaining studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 9 N.m (80 lb in). 4. Install the air cleaner outlet resonator adapter stud. Tighten Tighten the studs to 8 N.m (71 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3480 5. Connect the TP sensor harness connector. 6. Connect the IAC valve harness connector. 7. Install the accelerator control cable bracket using the fasteners. Tighten Tighten the fasteners to 12 N.m (106 lb in). 8. Install the accelerator cable. IMPORTANT: Ensure the accelerator and the cruise control cables do not hold the throttle open. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3481 9. Install the cruise control cable. 10. Install the air cleaner outlet resonator. 11. Install the engine cover. 12. Connect the negative battery cable. 13. Use the following procedure in order to check the accelerator pedal operation. 13.1. Depress the pedal to the floor. 13.2. Release the accelerator pedal. IMPORTANT: The accelerator pedal should operate freely without binding between full and closed throttle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3482 Throttle Body: Service and Repair Throttle Body Cleaning Procedure 1. Remove the air cleaner outlet duct. 2. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or an equivalent product. 1. If the deposits are excessive, remove and disassemble the throttle body for cleaning. 2. After disassembly, clean the throttle body using a parts cleaning brush. DO NOT immerse the throttle body in any cleaning solvent. 3. If you removed and disassembled the throttle body for cleaning, assemble and install the throttle body. NOTE: Do not subject a throttle body assembly which contains the following components to an immersion cleaner or a strong solvent: - Throttle position (TP) sensor - Idle air control (IAC) valve - Sealed throttle shaft bearings The cleaners will damage the electric components or sensors. The cleaners will damage some of these components that contain seals or O-rings. Solvents can wash away or break down the grease used on non-serviceable throttle shaft bearings. Never use a wire brush or scraper to clean the throttle body. A wire brush or sharp tools may damage the throttle body components. Do not use a cleaner that contains methyl ethyl ketone. This extremely strong solvent may damage components and is not necessary for this type of cleaning. 4. Install the air cleaner outlet duct. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair ACCELERATOR CONTROLS CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine cover. 2. Remove the air cleaner outlet duct. 3. Remove the accelerator cable from the throttle lever. 4. Remove the accelerator cable from the engine cable bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3486 5. Remove the accelerator cable (1) from the accelerator pedal (3). 6. Remove the accelerator cable assembly from the bulkhead (1). INSTALLATION PROCEDURE 1. Install the accelerator cable to the bulkhead (1). - Ensure all locking tabs (3) are expanded to secure cable assembly to dash panel (1). - Ensure dash panel insulator does not come in contact with any portion of the cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3487 2. Install the accelerator cable (1) to the accelerator pedal (3). Ensure the retainer (2) is securely seated to the accelerator pedal. 3. Install the accelerator cable to the engine cable bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3488 4. Install the accelerator cable to the throttle lever. 5. Install the air cleaner outlet duct. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3492 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3493 Throttle Position (TP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3494 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. 4. Remove the TP sensor and gasket from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3495 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. 2. Install the TP sensor mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3500 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3501 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3502 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3503 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3504 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3505 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3506 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3507 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3508 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3517 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3523 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3524 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3525 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3530 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3536 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3537 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3538 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3539 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3540 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3541 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3544 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3545 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3546 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3547 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3556 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3557 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3563 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3564 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > Page 3565 Distributor: Testing and Inspection DISTRIBUTOR INSPECTION 1. Remove the engine cover. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 2. Remove the 2 screws from the rotor. 3. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3568 4. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 5. Line up the square-cut hole in the vane wheel with the CMP sensor. 6. Remove the 2 screws that hold the camshaft position (CMP) sensor. 7. Discard the screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3569 8. Remove the CMP sensor. 9. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 10. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 11. Drive out the roll pin with a suitable punch. 12. Remove the driven gear from the distributor shaft. 13. Remove the round washer. 14. Remove the tang washer. 15. Remove the shim washer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3570 16. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Insert the sensor into the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3571 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3572 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3573 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3574 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. - Twist each spark plug wire 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3575 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3576 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3577 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3578 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 15. Install the engine cover. INSTALLATION PROCEDURE 2 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3579 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: The distributor driven gear - The distributor shaft - The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 2. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3580 3. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. 4. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 25 N.m (18 lb ft). 5. Install the distributor cap. 6. Install the new distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3581 Tighten Tighten the screws to 2.4 N.m (21 lb in). 7. Install the electrical connector to the distributor. 8. Install the spark plug wires to the distributor cap. 9. Install the ignition coil wire. Note the correct orientation of the wire boot. 10. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 11. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 3585 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots 1/2 turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Ignition Coil Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3589 Ignition Coil: Description and Operation The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3590 Ignition Coil: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connectors. 3. Remove the ignition coil wire to the distributor. 4. Remove the studs holding the bracket and the ignition coil to the intake manifold. 5. Remove the bracket and the ignition coil. 6. Drill and punch out the two rivets holding the ignition coil to the bracket. 7. Remove the ignition coil from the bracket. INSTALLATION PROCEDURE 1. Install the ignition coil to the bracket with the 2 screws. IMPORTANT: A replacement ignition coil kit comes with 2 screws in order to attach the ignition coil to the bracket. 2. Install the ignition coil and the bracket to the intake manifold with studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 11 N.m (97 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3591 3. Install the ignition coil wire. The wire must not touch anything like the dip stick. Rubbing will make a ground or short after time of use. 4. Install the electrical connectors. 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 3595 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 3596 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 3597 Ignition Control Module (ICM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 3598 Ignition Control Module: Description and Operation The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 3599 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3603 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3604 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3605 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3606 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3611 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3612 Engine Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3613 Ignition Control Module (ICM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3614 Ignition Control Module: Description and Operation The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3615 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3620 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3621 Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3622 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3623 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 4. Remove the distributor cap screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3624 5. Remove the distributor cap. 6. Remove the rotor screws. 7. Remove the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3625 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3626 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3627 4. Install new rotor screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3628 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3637 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3643 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3644 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3645 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3650 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3656 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3657 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft Position Sensor: > 03-06-04-033A > Feb > 03 > Engine Controls - Revised DTC P0336 > Page 3658 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3659 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3660 Crankshaft Position (CKP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3661 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTC's with a scan tool. If other DTC's are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTC's set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3664 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. 4. Disconnect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3665 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTC's. 1. Replace the CKP sensor O-ring. IMPORTANT: Do not reuse the original O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3666 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3667 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3671 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3672 Knock Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3673 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3674 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and the knock sensor bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug: Electrical Specifications Spark Plug Wire Resistance................................................................................................................. ........................................................1,000 ohms per ft Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 3679 Spark Plug: Mechanical Specifications Spark Plug Gap 0.060 in. 1.52 mm Spark Plug Torque Used Heads 15 Nm 11 lb. ft. New Aluminum Heads 20 Nm 15 lb. ft. New Iron Heads 30 Nm 22 lb. ft. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3680 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ....................................................... AC Type 41-932 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3681 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3682 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3683 - Incorrect combustion - Reduced ignition system voltage output - Weak coils - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3684 Spark Plug: Service and Repair REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed. Specification Spark plug gap: 1.524 mm (0.060 in). 3. Hand start the spark plugs in the corresponding cylinders. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plugs. Tighten For used heads tighten the spark plugs to 15 N.m (11 lb ft). - For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). - For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 1. Install the spark plug wires. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3692 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3693 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3694 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3695 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3696 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3697 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3701 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3702 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3703 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3704 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3705 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the A/T shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the A/T shift lock control actuator from the steering column jacket assembly. 6. Remove the AT shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the A/T shift lock control actuator onto the steering column jacket assembly. 2. Connect the A/T shift lock control actuator electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3706 3. Adjust the A/T shift lock control actuator with the shift lever clevis in the neutral position: 3.1. Pull out the tab (1) on the adjuster block side (2) of the AT shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the A/T shift lock control actuator for the following items: 4.1. The AT shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the AT shift lock control actuator if needed. 5. Install the lower steering column trim cover. 6. Enable the SIR system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3712 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3713 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3714 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 3717 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 3718 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3719 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3720 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3721 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3722 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3727 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3728 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3729 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side > Page 3732 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3733 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Tools Required ^ J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3734 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3735 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3736 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3737 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 3744 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 3745 Control Module: Locations Transfer Case Shift Control Module Transfer Case Shift Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 3746 Control Module: Service and Repair Transfer Case Shift Control Module REMOVAL 1. Remove the parking brake assembly mounting bolts only and lay the parking brake assembly aside. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 3747 2. Remove the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 3748 3. Remove the electrical connectors from the control module. 4. Remove the mounting screws for the control module. 5. Remove the control module from the mounting bracket. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 3749 1. Install the control module in the mounting bracket. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct park number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the mounting screws for the control module. 3. Tighten the mounting screws to 6 Nm (53 lb.in). 4. Install the electrical connectors in the control module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 3750 5. Install the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 3751 6. Install the parking brake assembly. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Part 1 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 3757 Part 2 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 3762 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 3763 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 3764 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3765 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 3769 Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 3770 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3774 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3775 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3776 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3777 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3778 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 3783 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 3784 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 3785 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 3791 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 3792 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 3793 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 05-06-04-077 > Dec > 05 > Engine Controls - Lack of Power When Hot PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Lack of Power When Hot Bulletin No.: 05-06-04-077 Date: December 22, 2005 TECHNICAL Subject: Lack of Power (LU3 Engine) at High Ambient Temperatures Only (If Necessary, Reprogram PCM with New Service Calibration) Models: 2003-2005 Chevrolet Astro, Blazer, Express, S-10, Silverado 2003-2005 GMC Jimmy, Safari, Savana, Sierra, Sonoma with 4.3L Vortec(TM) V6 Engine (VIN X - RPO LU3) Condition Some customers may comment that the vehicle may exhibit a lack of power at high ambient temperatures. Cause Engineering has identified a concern with the PCM software. In high ambient temperatures, the engine control management system may falsely retard the timing, causing a noticeable loss of power. Correction Important: Before Reprogramming the PCM, verify the customer concern. Refer to SI Engine Controls and under Diagnostic Information and Procedures. Refer to Lack of Power, Sluggishness, or Sponginess for the cause of the low power condition at high ambient temperatures. If no trouble is found, then reprogram the PCM. Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 12.5, which was broadcast to dealers on 12/11/2005. For the dealerships that use CDs, the CD version will be 1.0 for 2006, which will be mailed 0111212006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate PROM - Programmable Read Only Memory: Customer Interest A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate > Page 3811 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-06-04-077 > Dec > 05 > Engine Controls - Lack of Power When Hot PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Lack of Power When Hot Bulletin No.: 05-06-04-077 Date: December 22, 2005 TECHNICAL Subject: Lack of Power (LU3 Engine) at High Ambient Temperatures Only (If Necessary, Reprogram PCM with New Service Calibration) Models: 2003-2005 Chevrolet Astro, Blazer, Express, S-10, Silverado 2003-2005 GMC Jimmy, Safari, Savana, Sierra, Sonoma with 4.3L Vortec(TM) V6 Engine (VIN X - RPO LU3) Condition Some customers may comment that the vehicle may exhibit a lack of power at high ambient temperatures. Cause Engineering has identified a concern with the PCM software. In high ambient temperatures, the engine control management system may falsely retard the timing, causing a noticeable loss of power. Correction Important: Before Reprogramming the PCM, verify the customer concern. Refer to SI Engine Controls and under Diagnostic Information and Procedures. Refer to Lack of Power, Sluggishness, or Sponginess for the cause of the low power condition at high ambient temperatures. If no trouble is found, then reprogram the PCM. Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 12.5, which was broadcast to dealers on 12/11/2005. For the dealerships that use CDs, the CD version will be 1.0 for 2006, which will be mailed 0111212006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate > Page 3821 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3829 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3830 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3831 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3832 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3833 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3834 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3838 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3839 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3840 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3841 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3842 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the A/T shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the A/T shift lock control actuator from the steering column jacket assembly. 6. Remove the AT shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the A/T shift lock control actuator onto the steering column jacket assembly. 2. Connect the A/T shift lock control actuator electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3843 3. Adjust the A/T shift lock control actuator with the shift lever clevis in the neutral position: 3.1. Pull out the tab (1) on the adjuster block side (2) of the AT shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the A/T shift lock control actuator for the following items: 4.1. The AT shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the AT shift lock control actuator if needed. 5. Install the lower steering column trim cover. 6. Enable the SIR system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3849 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3850 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3851 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 3854 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 3855 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3856 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3857 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3858 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3859 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3864 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3865 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3866 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side > Page 3869 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3870 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Tools Required ^ J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3871 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3872 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3873 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3874 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3881 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3882 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3883 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3884 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3885 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3886 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3890 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3891 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3892 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3893 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3894 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the A/T shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the A/T shift lock control actuator from the steering column jacket assembly. 6. Remove the AT shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the A/T shift lock control actuator onto the steering column jacket assembly. 2. Connect the A/T shift lock control actuator electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3895 3. Adjust the A/T shift lock control actuator with the shift lever clevis in the neutral position: 3.1. Pull out the tab (1) on the adjuster block side (2) of the AT shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the A/T shift lock control actuator for the following items: 4.1. The AT shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the AT shift lock control actuator if needed. 5. Install the lower steering column trim cover. 6. Enable the SIR system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3901 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3902 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3903 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 3906 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 3907 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3908 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3909 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3910 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3911 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3916 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3917 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 3918 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side > Page 3921 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3922 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Tools Required ^ J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3923 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3924 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3925 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3926 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 3931 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 3932 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 3933 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 3934 Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets Tools Required ^ J 25025-B Pump and Valve Body Alignment Pin Set ^ J 36850 Transjel Lubricant Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. Important: The 1-2 accumulator can be removed without removing the control valve assembly. 3. Remove the control valve body. 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2 accumulator cover assembly. 6. Disassemble the 1-2 accumulator. 6.1. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. 6.2. Remove the 1-2 accumulator inner and outer springs. 7. Inspect the 1-2 accumulator inner and outer springs for cracks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 3935 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support retaining bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 3936 Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin 12. Remove the spacer plate support. 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following defects: ^ Porosity Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 3937 ^ Cracks ^ Scoring ^ Nicks and scratches Installation Procedure 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 3938 4. Install the J 25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 23 are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. Notice: Refer to Fastener Notice in Service Precautions.. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 3939 10. Install the spacer plate support and the spacer plate support retaining bolts. Tighten the spacer plate support retaining bolts to 11 Nm (97 inch lbs.). 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 3940 13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. 14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover. 15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. Tighten the accumulator cover retaining bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the control valve body. 18. Install the transmission oil pan and filter. 19. Lower the vehicle. 20. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 3949 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Band Apply Servo: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3954 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3955 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 3961 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3966 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3967 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 3968 Band Apply Servo: Service and Repair 2-4 Servo Tools Required ^ J 29714-A Servo Cover Depressor Removal Procedure 1. Raise the vehicle. 2. Remove the transmission heat shield. 3. Place a drain pan under the vehicle. 4. Remove the oil pan bolt below and to the left of the 2 - servo cover. 5. Install the J 29714-A to the oil pan rail. 6. Tighten the bolt on the J 29714-A in order to compress the servo cover. 7. Remove the servo cover retaining ring. 8. Loosen the bolt on the J 29714-A to release tension on the servo cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 3969 9. Remove the servo cover and 9-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 10. Remove the 2-4 servo assembly from the transmission. 11. Inspect the 4th apply piston, the 2-4 servo converter, 2nd apply piston, and the piston inner housing for the following defects: ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install the new seals on the pistons and the servo cover. 2. Lubricate the seals with clean transmission fluid. 3. Install the 2-4 servo assembly into the 2-4 servo bore. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 3970 4. Install the servo cover and O-ring seal. 5. Install the J 29714-A. 6. Tighten the bolt on the J 29714-A in order to compress the servo cover. 7. Install the servo cover retaining ring. 8. Remove the J 29714-A from the oil pan flange. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the oil pan bolt. Tighten the oil pan bolt to 11 Nm (97 inch lbs.). 10. Install the transmission heat shield. 11. Remove the drain pan. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Part 1 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Locations > Page 3974 Part 2 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 3979 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 3980 Case: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 3981 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 3982 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 3983 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 3984 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 3993 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Channel Plate: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3998 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3999 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4009 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Channel Plate: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4014 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4015 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4029 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4030 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4040 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4041 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O-ring seal (3). Installation Procedure 1. Install a new case extension O-ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). Tighten the case extension bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 4053 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 4054 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 4055 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 4056 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4059 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4060 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4061 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4062 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4063 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant; GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4067 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4068 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4069 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant; GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 4074 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 4075 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 4076 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the oil cooler lines from the radiator. 3. Remove the oil cooler lines from the transmission. 4. Remove the oil cooler lines from the mounting bracket. 5. Remove the cooler lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler line to the vehicle. 2. Install the oil cooler lines to the mounting bracket. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is any excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. 3. Connect the oil cooler lines to the transmission. 4. Connect the oil cooler lines to the radiator. 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4079 Fluid Line/Hose: Service and Repair Transmission Oil Cooler Line Quick Connect Fitting Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure Important: Perform the following procedures when removing the retaining ring and cooler line from the quick connect fitting on the radiator and transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about two inches. 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4080 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is any excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4081 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4082 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4083 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Inspect and fill the fluid level as necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Tighten the oil pan to transmission case bolts alternately and evenly. Transmission Oil Pan to Case Bolt .......................................................................................................................................... 9.5 13.8 Nm (7 - 10 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4091 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4092 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4093 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4094 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4099 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4100 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4101 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4102 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4103 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4104 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4105 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4106 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4107 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Diagrams > Park/Neutral Position Switch (C1) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Diagrams > Park/Neutral Position Switch (C1) > Page 4116 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Diagrams > Page 4117 Parking Pawl: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Diagrams > Page 4118 Parking Pawl: Service and Repair Park/Neutral Position Switch Replacement Tools Required ^ J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual, shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of; neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Diagrams > Page 4119 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4124 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4125 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4126 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4127 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4128 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4129 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4138 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4144 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4149 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4150 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4151 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4152 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4158 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4159 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4160 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4161 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4162 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4163 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4164 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transmission Extension Housing Rear Oil Seal Replacement Seals and Gaskets: Service and Repair Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement Tools Required ^ J 21426 Extension Housing Seal Installer ^ J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transmission Extension Housing Rear Oil Seal Replacement > Page 4167 Seals and Gaskets: Service and Repair Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Remove the transmission fluid level indicator from the fluid fill tube. 2. Remove the bolt securing the transmission fluid fill tube bracket to the engine. 3. Raise the vehicle. 4. Remove the bolt securing the transmission fluid fill tube bracket to the transmission. 5. Place a drain pan under the vehicle. 6. Remove the transmission fluid fill tube from the transmission. 7. Remove the transmission fill tube seal. Installation Procedure 1. Install a new oil level indicator tube seal into the transmission case. 2. Install the oil level indicator tube into the seal. Notice: Refer to Fastener Notice in Caution and Notices. 3. Install the bolt securing the oil level indicator tube bracket to the transmission. Tighten the bolt to 47 Nm (35 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Lower the vehicle. 6. Install the bolt securing the oil level indicator tube bracket to the engine. Tighten the bolt to 6 Nm (53 inch lbs.). 7. Fill the transmission with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transmission Extension Housing Rear Oil Seal Replacement > Page 4168 Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement Tools Required ^ J 43911 Selector Shaft Seal Remover ^ J 43909 Selector Shaft Seal Installer Removal Procedure 1. Raise the vehicle. 2. Remove the Park/Neutral Position (PNP) Switch. 3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Part 1 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Locations > Page 4173 Part 2 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4178 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4179 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4180 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4181 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4185 Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4186 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4190 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4191 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4192 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4193 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4194 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4199 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4200 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4201 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4207 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4208 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4209 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4214 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4215 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4216 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4217 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4218 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the A/T shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the A/T shift lock control actuator from the steering column jacket assembly. 6. Remove the AT shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the A/T shift lock control actuator onto the steering column jacket assembly. 2. Connect the A/T shift lock control actuator electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4219 3. Adjust the A/T shift lock control actuator with the shift lever clevis in the neutral position: 3.1. Pull out the tab (1) on the adjuster block side (2) of the AT shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the A/T shift lock control actuator for the following items: 4.1. The AT shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the AT shift lock control actuator if needed. 5. Install the lower steering column trim cover. 6. Enable the SIR system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4225 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4226 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4227 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 4230 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 4231 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4232 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4233 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4234 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4235 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Shift Cable: Customer Interest A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate > Page 4245 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Shift Cable: All Technical Service Bulletins A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-029 > Jun > 04 > A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate > Page 4251 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4257 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4258 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4259 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4265 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4266 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4267 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4268 Shift Cable: Adjustments Automatic Transmission Range Selector Cable Adjustment Adjustment Procedure 1. Ensure that the transmission range selector cable is not restricted. 2. Block the drive wheels. 3. Place the steering column shift lever in the NEUTRAL position. 4. Raise the vehicle. 5. Ensure that the transmission is in the mechanical neutral position. 6. Disconnect the transmission range selector cable from the transmission range selector lever ball stud. 7. Rotate the transmission range selector lever clockwise until it reaches the full clockwise stop position. 8. Move the range selector lever counterclockwise two detents. 9. Release the locking tab located on the range selector cable. 10. Ensure that the tab remains positioned OUT. 11. Pull the cable end completely forward and release it. (When the cable is pulled completely forward and released, the adjustment spring will position the cable to its most rearward position.) 12. Connect the end of the range selector cable to the transmission range selector lever stud ball. 13. Press the locking tab IN in order to retain the adjustment. 14. Lower the vehicle. 15. Check for proper operation of the range selector cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4269 Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Block the drive wheels and place the vehicle in the neutral position. 2. Remove the drivers side knee bolster. 3. Remove the bottom half of the steering column trim cover. 4. Remove the range selector cable end from the steering column shift controller ball stud. 5. Remove the clip that secures the range selector cable to the steering column bracket. 6. Remove the range selector cable from the steering column bracket. 7. Raise the vehicle. 8. Remove the range selector cable end from the transmission range selector lever stud ball. 9. Remove the clip from the bracket that secures the range selector cable to the transmission. 10. Remove the range selector cable from the bracket. 11. Remove the three range selector cable clips from the body. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4270 12. Remove the grommet from the hole in the floor panel. 13. If the vehicle is equipped with a transfer case, remove the bolt and washer securing the clip and the range selector cable to the transfer case. 14. Remove the range selector cable from the vehicle. Installation Procedure 1. Feed the steering column end of the range selector cable through the grommet hole in the floor panel. 2. Lower the vehicle. 3. Connect the range selector cable end to the steering column shift controller stud ball. 4. Install the range selector cable to the steering column bracket. 5. Install the clip that secures the range selector cable to the steering column bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4271 6. Raise the vehicle. 7. Install the range selector cable to the transmission bracket. ^ Do not depress the adjustment locking tab located on the range selector cable. Ensure that the tab remains positioned OUT. ^ Do not install the range selector cable end to the transmission shift lever stud ball at this time. 8. Ensure that the transmission is in the mechanical neutral position. ^ Rotate the transmission range selector lever clockwise until it reaches the full clockwise stop position. ^ Move the range selector lever counterclockwise two detents. 9. Position the range selector cable to assume a natural routing. The range selector cable must be free to move 20.0 mm (0.80 inch) axially during the adjustment under adjustment spring loads. 10. Pull the range selector cable end completely forward and release it. (When the cable is pulled completely forward and released, the adjustment spring will position the cable to its most rearward position.) Notice: Do not pull the shift lever ball stud forward of the transmission shift lever ball stud during installation. Pulling the shift cable end forward of Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4272 the transmission shift lever ball stud before installing the shift cable end to the transmission shift lever ball stud will result in a poor adjustment. 11. Connect the end of the range selector cable to the transmission range selector lever stud ball. 12. Press the locking tab IN in order to retain the adjustment and to secure the cable to the transmission bracket. 13. If the vehicle is equipped with a transfer case, install the bolt and washer securing clip and the cable to the transfer case. 14. Install the grommet to the hole in the floor panel. 15. Install the three range selector cable clips to the body. 16. Lower the vehicle. 17. Check for proper operation of the range selector cable. 18. Install the lower half of the steering column trim cover. 19. Install the drivers side knee bolster. 20. Remove the wheel blocks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4281 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4282 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4288 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4289 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 4294 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 4299 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4304 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4305 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4306 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side > Page 4309 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4310 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Tools Required ^ J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4311 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4312 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4313 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4314 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4319 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4320 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4321 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4322 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4323 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4324 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4325 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4329 Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4330 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Mount Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 4334 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ For RWD vehicles, tighten the bolts to 61 Nm (45 ft. lbs.). ^ For AWD vehicles, tighten the bolts to 85 Nm (63 ft. lbs.). 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. Tighten the nut or nuts to 45 Nm (33 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4338 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4339 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4340 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4341 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4342 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4347 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4348 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4349 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4355 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4356 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4357 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 4366 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Valve Body: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4371 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4372 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4382 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4383 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4384 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4385 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4386 Left Side Control Valve Body Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4387 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4388 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4389 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 4394 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 4399 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 4400 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 4401 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Valve Body: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4406 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4407 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4417 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4418 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4419 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4420 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4421 Left Side Control Valve Body Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4422 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4423 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 4424 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 4429 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 4430 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 4431 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4432 Valve Body: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4433 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4434 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4435 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4436 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4437 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4438 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4439 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4440 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4441 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > System Information > Technical Service Bulletins > M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Specifications Differential Carrier: Specifications Fastener Tightening Specifications Carrier Assembly to Frame Mounting Bolts ........................................................................................................................................ 85 Nm (63 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Fastener Tightening Specifications Left Side Cover to Carrier Assembly Bolts ......................................................................................................................................... 18 Nm (13 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4459 Differential Cover: Service and Repair Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Clean the rear axle cover area. 3. Remove the rear axle cover bolts. Place a container under the axle housing in order to retrieve the lubricant. 4. Remove the rear axle cover from the axle housing. Pry the rear axle cover loose. 5. Drain the lubricant from the axle housing. 6. Remove the fill plug. 7. Clean the gasket surfaces on the axle housing and the rear axle cover. Installation Procedure 1. Install the new gasket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4460 2. Install the rear axle cover. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle cover bolts. Tighten the bolts to 30 Nm (22 ft. lbs.) in a crosswise pattern. 4. Add axle lubricant to the axle housing. Use the proper fluid. 5. Install the fill plug. Tighten the fill plug to 33 Nm (24 ft. lbs.). 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Front Drive Axle Differential Axle Housing: Specifications Front Drive Axle Fastener Tightening Specifications Inner Axle Shaft Housing to Differential Carrier Bolts ....................................................................................................................... 48 Nm (36 ft. lbs.) Inner Axle Shaft Housing to Frame Bracket Nuts ............................................................................................................................... 73 Nm (54 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Front Drive Axle > Page 4465 Differential Axle Housing: Specifications Rear Drive Axle Fastener Tightening Specifications Differential Housing Cover Bolts ........................................................................................................................................................ 30 Nm (22 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Page 4466 Differential Axle Housing: Service and Repair Rear Axle Housing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the axle lubricant. 3. Remove the rear axle assembly. 4. Remove the brake drums. 5. Remove the rear axle cover housing and gasket. 6. Remove the axle shafts. 7. Remove the brake backing plates. 8. Remove the differential. 9. Remove the drive pinion. 10. Remove the drive pinion shaft yoke and the seal. Installation Procedure 1. Install the drive pinion. 2. Install the differential case. 3. Adjust the side bearing preload. 4. Adjust the backlash. 5. Perform a gear tooth contact pattern check. 6. Install the brake backing plates. 7. Install the axle shafts. 8. Install the rear axle housing cover and gasket. 9. Install the brake drums. 10. Install the rear axle. 11. Fill the axle with lubricant. 12. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications Drain Plug: Specifications Fastener Tightening Specifications Axle Drain Plug .................................................................................................................................... ............................................... 30 Nm (22 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Front Drive Axle Fill Plug: Specifications Front Drive Axle Fastener Tightening Specifications Axle Fill Plug ........................................................................................................................................ ............................................... 30 Nm (22 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Front Drive Axle > Page 4474 Fill Plug: Specifications Rear Drive Axle Fastener Tightening Specifications Fill Plug ................................................................................................................................................ ............................................... 33 Nm (24 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 4479 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Axle ............................................................................................................................................ ................................................. 1.2 Liters (2.6 Pints) Rear Axle (Standard) ........................................ ..................................................................................................................................... 1.7 Liters (3.5 Pints) Rear Axle (Locking) ................................................................................................................... ........................................................... 1.7 Liters (3.5 Pints) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4482 Fluid - Differential: Fluid Type Specifications Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Rear Differential Differential Fluid Type Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle Fluid - Differential: Service and Repair Front Drive Axle Lubricant Change Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the fill plug and the washer. 3. Remove the drain plug and the washer. 4. Drain the fluid from the front axle differential. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 4485 1. Install the drain plug and the washer. Tighten the drain plug to 33 Nm (24 ft. lbs.). 2. Fill the front differential with lubricant. Use the proper fluid. 3. Install the fill plug and the washer. Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 4486 Fluid - Differential: Service and Repair Rear Drive Axle Lubricant Level Check Lubricant Level Check 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. Specification The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. Lubricant Change Lubricant Change Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 4487 3. Remove the rear axle housing cover and the rear axle housing cover gasket. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Install the new rear axle housing cover gasket and the rear axle housing cover. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear axle housing cover bolts. Tighten the rear axle housing cover bolts to 30 Nm (22 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 4488 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle Pinion Bearing: Specifications Front Drive Axle Pinion Preload and Backlash Backlash .............................................................................................................................................. ......................... 0.08 - 0.25 mm (0.003" - 0.010") Backlash (Preferred) ..................................................................................................................................................... 0.13 - 0.18 mm (0.005" - 0.007") Pinion Bearing Preload (New Bearings) .......................................................................................................................... 1.7 - 3.4 Nm (15 - 30 inch lbs.) Pinion Bearing Preload (Used Bearings) ......................................................................................................................... 1.1 - 2.8 Nm (10 - 25 inch lbs.) Pinion and Differential Case Bearing Preload (New Bearings) ....................................................................................... 3.4 - 6.2 Nm (30 - 55 inch lbs.) Pinion and Differential Case Bearing Preload (Used Bearings) ...................................................................................... 2.8 - 5.6 Nm (25 - 50 inch lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle > Page 4493 Pinion Bearing: Specifications Rear Drive Axle Pinion Bearing and Differential Bearing Preload Pinion and Differential Case Bearing Preload, New Bearings ......................................................................................... 3.4 - 6.2 Nm (30 - 55 inch lbs.) Pinion and Differential Case Bearing Preload, Used Bearings ........................................................................................ 2.8 - 5.6 Nm (25 - 50 inch lbs.) Pinion Bearing Preload, New Bearings ........................................................................................................................... 1.7 - 3.4 Nm (15 - 30 inch lbs.) Pinion Bearing Preload, Used Bearings ........................................................................................................................... 1.1 - 2.8 Nm (10 - 25 inch lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Page 4494 Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement ^ Tools Required J 5590 Pinion Bearing Race Installer - Rear - J 7817 Bearing Installer - J 8092 Driver Handle - J 22912-01 Split-Plate Bearing Puller - J 29609 Rear Pinion Bearing Cup Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake drums. 4. Remove the axle shafts. 5. Remove the differential. 6. Remove the drive pinion from the axle. 7. Press the bearing off of the pinion using the J 22912-01. 8. Remove the shim. 9. Remove the drive pinion bearing cups from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Installation Procedure 1. Install the outer pinion bearing cup using the J 7817 (2) and the J 8092 (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Page 4495 2. Install the inner pinion bearing cup using the J 29609 (2), and the J 8092 (1). 3. Determine the selective shim thickness for the pinion. 4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5. Install the inner pinion bearing using the J 5590. Press the bearing on until the cone seats on the pinion shim. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearing with axle lubricant. Use the proper fluid. 8. Install the pinion into the axle housing. 9. Install the outer pinion bearing onto the pinion. 10. Install a new pinion oil seal and the pinion yoke. 11. Install the differential. 12. Install the brake drums. 13. Install the tire and wheel assemblies. 14. Fill the axle with lubricant. Use the proper fluid. 15. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle Ring Gear: Specifications Front Drive Axle Fastener Tightening Specifications Ring Gear to Case Mounting Bolts ...................................................................................................................................................... 80 Nm (59 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 4500 Ring Gear: Specifications Rear Drive Axle Fastener Tightening Specifications Ring Gear Bolts ................................................................................................................................... .............................................. 120 Nm (89 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inner Axle Seal and/or Bearing Replacement - Front Drive Axle Seals and Gaskets: Service and Repair Inner Axle Seal and/or Bearing Replacement - Front Drive Axle Inner Axle Seal and/or Bearing Replacement - Front Drive Axle ^ Tools Required J 23907 Slide Hammer - J 29369-1 Bushing and Universal Remover - J 42211 Axle Bearing Installer - J 42738 Seal Installer - J 8092 Driver Handle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the left or the right wheel drive shaft as necessary. Important: Do not damage the case. 3. If replacing the left side seal and/or bearing, perform the following steps: 3.1. Remove the left inner axle shaft. 3.2. Remove the inner axle shaft seal cover. 3.3. Install the J 29369-1 to the backside of the inner axle shaft bearing. 3.4. Install the J 23907 to the J 29369-1. 3.5. Remove the inner axle shaft bearing by pulling on the J 23907. 4. Mount the inner axle shaft seal cover in a vise. 5. Install the J 29369-1 to the backside of the inner axle shaft seal. 6. Install the J 23907 to the J 29369-1. 7. Remove the inner axle shaft seal by pulling on the J 23907. 8. If replacing the right side seal and/or bearing, perform the following steps: 8.1. Remove the inner axle shaft and housing assembly. 8.2. Remove the inner axle shaft from the inner axle shaft housing. 8.3. Install the J 29369-1 (2) to the backside of the bearing. 8.4. Install the J 23907 (1) to the J 29369-1 (2). 8.5. Remove the bearing and the seal by pulling on the J 23907 (1). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inner Axle Seal and/or Bearing Replacement - Front Drive Axle > Page 4505 1. If installing the right side bearing and/or seal, perform the following steps: 1.1. Install the bearing with the square shoulder in using the J 42211 and the J 8092. 1.2. Install the new axle shaft seal using the J 42738. 1.3. Install the inner axle shaft to the inner axle shaft housing. 1.4. Install the inner axle shaft and housing assembly. 2. If installing the left side bearing and/or seal, perform the following steps: 2.1. Install the bearing with the square shoulder in using the J 42211 and the J 8092. 2.2. Install the new axle shaft seal into the inner axle shaft seal cover using the J 23911. 3. Install the inner axle shaft seal cover. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the inner axle shaft seal cover bolts. Tighten the inner axle shaft seal cover to 25 Nm (18 ft. lbs.). 5. Install the left inner axle shaft. Carefully tap the inner axle shaft into place with a soft mallet. 6. Install the wheel drive shaft. 7. Inspect the axle lubricant level and add, if necessary. 8. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inner Axle Seal and/or Bearing Replacement - Front Drive Axle > Page 4506 Seals and Gaskets: Service and Repair Rear Oil Seal and/or Bearing Replacement Rear Oil Seal and/or Bearing Replacement ^ Tools Required J 8092 Driver Handle - J 23771 Axle Shaft Seal Installer - J 34794 Bearing Installer - J 23689 Axle Shaft Bearing Remover - J 2619-01 Slide Hammer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 23689 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 34794 (1) and the J 8092 (2). Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inner Axle Seal and/or Bearing Replacement - Front Drive Axle > Page 4507 2. Install the axle shaft seal using the J 23771. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 3. Install the axle shaft. 4. Install the rear axle housing cover. 5. Install the tire and wheel assembly. 6. Fill the rear axle. Use the proper fluid. 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds Vibration Damper: Customer Interest Drivetrain - Booming Noise at Highway Speeds Bulletin No.: 00-03-09-001A Date: July 29, 2003 TECHNICAL Subject: Rolling Boom Noise Inside Vehicle (Install Pinion Nose Damper and/or New Rear Leaf Spring Dampers) Models: 1995-2004 Chevrolet Astro Van Models 1995-2004 GMC Safari Van Models Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-03-09-001 (Section 03 - Suspension). Condition Some owners may comment about a "boom" noise inside the vehicle while driving at speeds ranging between 97-105 km/h (60-65 mph). This condition is most noticeable from behind the driver's seat. Cause The condition may result from an engine-firing harmonic, which becomes noticeable at torque converter clutch (TCC) lock-up. Correction A new rear leaf spring damper kit (one per spring) has been developed, to be used in conjunction with a pinion nose damper tuned to 86 Hertz (Hz), to reduce the resultant noise level. AFFECTED VEHICLES MAY REQUIRE THE INSTALLATION OF THE PINION NOSE DAMPER, THE SPRING DAMPERS, OR BOTH. THE INSTALLATION OF EITHER OF THESE DAMPERS IS AT THE DISCRETION OF THE TECHNICIAN FOR BEST RESULTS. Use the following procedures and the appropriate part number listed below. Important: Installation of these dampers will not totally eliminate the boom noise. The boom noise may only be reduced to a more acceptable level. There may be other boom noises, such as body or exhaust, associated with the vehicle and this fix may either diminish or enhance the noise. These other noises should be addressed prior to the correction for the TCC boom dampener being installed. Pinion Nose Damper Installation Procedure Use Damper Kit, Rr. Axle Vib., P/N 15006567, for this procedure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4516 1. Place the template (1), P/N 15005879, on the bottom surface of the triangular flanged portion of the rear axle. 2. Mark the hole locations. 3. Using a pin punch (1), mark the center location of the holes. 4. Drill a 11 mm (0.44 in) diameter hole in two places. 5. Clean out the holes, including the top and bottom surface of the axle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4517 6. Install the rear axle pinion nose damper (1), P/N 15005880. 7. Install the rear axle pinion nose damper washers (2), P/N 15614758, and the nuts (3), P/N 11516072. Tighten Tighten each nut to 37-53 N.m (27-39 lb ft). 8. Rotate the driveshaft in order to verify that there is no contact between the driveshaft and the pinion nose damper. 9. Test drive the vehicle. Inspect for contact between the driveshaft and the damper. Rear Leaf Spring Damper Installation Procedure Use Damper Kit, Rear Spring Vib., P/N 15042486, for this procedure. 1. Raise the vehicle. Support the rear axle. Refer to the General Information subsection of the appropriate Service Manual for lifting and jacking information. 2. Remove the leaf spring. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 3. Locate the rear spring clip closest to the shackle. This clip maintains the alignment of the rear spring plates # 1 and # 2. Note: Do not damage the top surfaces of the # 1 and # 2 spring plates. Damage may cause premature spring breakage. 4. Insert a wood wedge, no metal or sharp objects, between rear spring plates # 1 and # 2, located forward of the clip. Allow enough clearance to work around. This should maximize the gap between spring plates # 1 and # 2. 5. Grind off or, using an 11 mm (0.44 in) drill bit, drill out the rivet head holding the clip to the # 2 spring plate. 6. Remove the clip and the plastic clip liner from the spring assembly. Discard the spring clip only. 7. Knock out any remaining rivet residue from spring plate # 2. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4518 8. Insert the stud bolt (2), P/N 15042491, from the top of spring plate # 2 (3) so that the bolt head sits into the hole's counter sink. 9. Place the spring clip (1), P/N 15042492, over the stud so that the clip is in a similar position as the original clip removed previously. Do not close the clip at this time. 10. Install the damper (8), P/N 15042487, onto the stud. Install the damper completely onto the stud so that the clip is securely trapped between the # 2 spring plate (bottom) and the damper inner sleeve. Tighten Tighten the damper to 30 N.m (22 lb ft) while holding the stud. 11. Install the jam nut (6), P/N 11508189, onto the stud until the nut is against the inner sleeve of the damper. Tighten Tighten the nut to 30 N.m (22 lb ft). Note: Do not break the clip liner or damage the top surface of the # 1 spring plate. 12. Install the plastic clip liner in the same orientation as when removed. The bolt head may stick up above the top surface of the spring plate. 13. Remove the wood wedge. 14. Using a press or a vise, close the clip to the same position as the removed clip. The maximum width of the installed clip is 91.5 mm (3.6 in) and the maximum height is 46.5 mm (1.8 in). This ensures proper clearance to the body rails. 15. Install the leaf spring onto the vehicle. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 16. Repeat steps 2-15 for the other spring. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4519 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds Vibration Damper: All Technical Service Bulletins Drivetrain - Booming Noise at Highway Speeds Bulletin No.: 00-03-09-001A Date: July 29, 2003 TECHNICAL Subject: Rolling Boom Noise Inside Vehicle (Install Pinion Nose Damper and/or New Rear Leaf Spring Dampers) Models: 1995-2004 Chevrolet Astro Van Models 1995-2004 GMC Safari Van Models Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-03-09-001 (Section 03 - Suspension). Condition Some owners may comment about a "boom" noise inside the vehicle while driving at speeds ranging between 97-105 km/h (60-65 mph). This condition is most noticeable from behind the driver's seat. Cause The condition may result from an engine-firing harmonic, which becomes noticeable at torque converter clutch (TCC) lock-up. Correction A new rear leaf spring damper kit (one per spring) has been developed, to be used in conjunction with a pinion nose damper tuned to 86 Hertz (Hz), to reduce the resultant noise level. AFFECTED VEHICLES MAY REQUIRE THE INSTALLATION OF THE PINION NOSE DAMPER, THE SPRING DAMPERS, OR BOTH. THE INSTALLATION OF EITHER OF THESE DAMPERS IS AT THE DISCRETION OF THE TECHNICIAN FOR BEST RESULTS. Use the following procedures and the appropriate part number listed below. Important: Installation of these dampers will not totally eliminate the boom noise. The boom noise may only be reduced to a more acceptable level. There may be other boom noises, such as body or exhaust, associated with the vehicle and this fix may either diminish or enhance the noise. These other noises should be addressed prior to the correction for the TCC boom dampener being installed. Pinion Nose Damper Installation Procedure Use Damper Kit, Rr. Axle Vib., P/N 15006567, for this procedure. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4525 1. Place the template (1), P/N 15005879, on the bottom surface of the triangular flanged portion of the rear axle. 2. Mark the hole locations. 3. Using a pin punch (1), mark the center location of the holes. 4. Drill a 11 mm (0.44 in) diameter hole in two places. 5. Clean out the holes, including the top and bottom surface of the axle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4526 6. Install the rear axle pinion nose damper (1), P/N 15005880. 7. Install the rear axle pinion nose damper washers (2), P/N 15614758, and the nuts (3), P/N 11516072. Tighten Tighten each nut to 37-53 N.m (27-39 lb ft). 8. Rotate the driveshaft in order to verify that there is no contact between the driveshaft and the pinion nose damper. 9. Test drive the vehicle. Inspect for contact between the driveshaft and the damper. Rear Leaf Spring Damper Installation Procedure Use Damper Kit, Rear Spring Vib., P/N 15042486, for this procedure. 1. Raise the vehicle. Support the rear axle. Refer to the General Information subsection of the appropriate Service Manual for lifting and jacking information. 2. Remove the leaf spring. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 3. Locate the rear spring clip closest to the shackle. This clip maintains the alignment of the rear spring plates # 1 and # 2. Note: Do not damage the top surfaces of the # 1 and # 2 spring plates. Damage may cause premature spring breakage. 4. Insert a wood wedge, no metal or sharp objects, between rear spring plates # 1 and # 2, located forward of the clip. Allow enough clearance to work around. This should maximize the gap between spring plates # 1 and # 2. 5. Grind off or, using an 11 mm (0.44 in) drill bit, drill out the rivet head holding the clip to the # 2 spring plate. 6. Remove the clip and the plastic clip liner from the spring assembly. Discard the spring clip only. 7. Knock out any remaining rivet residue from spring plate # 2. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4527 8. Insert the stud bolt (2), P/N 15042491, from the top of spring plate # 2 (3) so that the bolt head sits into the hole's counter sink. 9. Place the spring clip (1), P/N 15042492, over the stud so that the clip is in a similar position as the original clip removed previously. Do not close the clip at this time. 10. Install the damper (8), P/N 15042487, onto the stud. Install the damper completely onto the stud so that the clip is securely trapped between the # 2 spring plate (bottom) and the damper inner sleeve. Tighten Tighten the damper to 30 N.m (22 lb ft) while holding the stud. 11. Install the jam nut (6), P/N 11508189, onto the stud until the nut is against the inner sleeve of the damper. Tighten Tighten the nut to 30 N.m (22 lb ft). Note: Do not break the clip liner or damage the top surface of the # 1 spring plate. 12. Install the plastic clip liner in the same orientation as when removed. The bolt head may stick up above the top surface of the spring plate. 13. Remove the wood wedge. 14. Using a press or a vise, close the clip to the same position as the removed clip. The maximum width of the installed clip is 91.5 mm (3.6 in) and the maximum height is 46.5 mm (1.8 in). This ensures proper clearance to the body rails. 15. Install the leaf spring onto the vehicle. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 16. Repeat steps 2-15 for the other spring. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 4528 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement Constant Velocity Joint: Service and Repair Deflector Ring Replacement Deflector Ring Replacement Disassembly Procedure 1. Inspect the deflector ring (1). 2. Replace the deflector ring (1) if the deflector ring (1) is damaged. 3. Use a hammer and a brass drift to tap the damaged deflector ring (1) off of the CV joint. 4. Discard the deflector ring (1). Assembly Procedure ^ Tools Required 3 inch or 4 inch pipe coupling - 12 mm x 12 mm steel plate with a 28 mm hole drilled in the center. The plate must be at least 3 mm thick. - M24 x 2.0 nut 1. Put the new deflector ring (1) into position on the CV joint. 2. Put the 3 inch or 4 inch pipe coupling against the deflector ring (1). Put the 12 mm x 12 mm steel plate over the pipe. The halfshaft bar (2) will protrude through the 28 mm hole in the steel plate. 3. Install the M24 x 2.0 nut on the halfshaft bar. Tighten the M24 x 2.0 nut until the deflector ring (1) bottoms against the CV joint. 4. Remove the M24 x 2.0 nut, the 12 mm steel plate and the 3 inch or 4 inch pipe coupling. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4535 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement Tools Required - J 8059 Snap Ring Pliers (Parallel Jaw) - J 35910 Drive Axle Seal Clamp Plier - J 35566 Drive Axle Seal Clamp Plier Disassembly Procedure 1. Remove the large boot clamp (3) from the tripot boot (4) with side cutters. 2. Remove the tripot housing (1) and bushing (2) from the halfshaft bar (5). Wipe the grease off of the tripot assembly roller bearings and housing. 3. Remove bushing (2) from tripot housing (1) and discard bushing. 4. Degrease the housing (1) thoroughly. Use 320 grit 3M cloth (or equivalent) to remove any evident corrosion in the transmission booting surface. 5. Allow the housing (1) to dry prior to assembly. 6. Cut the small boot clamp from the halfshaft bar end of the tripot boot, using side cutters. Important: Handle the tripot spider assembly with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully. 7. Slide the tripot boot up the halfshaft bar (1), away from the tripot spider assembly toward the outboard (CV joint assembly) end of the halfshaft bar. 8. Spread the spider spacer ring (2) using J 8059 (or equivalent). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4536 9. Slide the spider spacer ring (3) and the tripot spider assembly (2) up on the halfshaft bar (4). This will provide access to the halfshaft bar retaining ring (1) which is in the groove at the end of the halfshaft bar (4). 10. Remove the retaining ring (1), spider assembly (2), spacer ring (3), and tripot boot (4). Discard the boot and rings. 11. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves). 12. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit. Assembly Procedure 1. Place the new small boot clamp (2) onto the small end of the joint boot (1). 2. Slide the tripot boot (1) and small boot clamp (2) into the proper position on the halfshaft bar. 3. Position the small end of the joint boot (1) into the joint boot groove (3) on the halfshaft bar. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4537 4. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Torque the small boot clamp (1) to 136 Nm (100 ft. lbs.). Check the gap dimension on the clamp ear. Important: Assemble the joint with the convolute retainer in the correct position. The boot will be damaged if the joint assembly does not meet the specified dimension. 5. Install the convolute, retainer over the inboard boot, capturing 3 convolutions. 6. Install the first spacer ring and tripot spider assembly onto the halfshaft bar. 7. Push the first spacer ring and the tripot spider assembly onto the halfshaft bar far enough to allow for installation of the second spacer ring in the groove at the end of the halfshaft bar. 8. Install the second spacer ring in the groove at the end of the halfshaft bar. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4538 9. Push the spider assembly (1) back toward the end of the halfshaft bar (3). 10. Move the spider spacer ring (2) back toward the end of the halfshaft bar. Seat the spider spacer ring (2) in the spacer ring groove. Make sure the spider spacer ring is fully seated. 11. Pack the tripot boot and the tripot housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 12. Place the large retaining clamp (2) on the boot. 13. Install the new bushing onto the housing (1). 14. Place the housing (1) over the spider assembly (3). 15. Install the boot onto the housing (1). 16. Check the inboard stroke position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4539 17. Secure the large retaining clamp (2) and the boot (3) to the housing (1) using J 35566. 18. Remove the convolute retainer from the boot (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4540 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement Tools Required ^ J 8059 Snap Ring Pliers ^ J 35910 Seal Clamp Tool ^ J 36652 Drive Axle Clamp Swage Tool Disassembly Procedure 1. Place protective covers over the vise jaws. 2. Place the halfshaft in the vise. 3. Use a hand grinder to cut through the swage ring (2). Do not damage the outer race (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4541 4. Slide the seal down the halfshaft bar (4) and away from the CV joint outer race (1). Wipe all of the grease away from the face of the CV joint. 5. Find the halfshaft bar retaining snap ring (2), which is located in the inner race (3). Spread the snap ring (2) ears apart using J 8059 (or equivalent). 6. Pull the CV joint and the CV joint seal from the halfshaft bar (4). Discard the old CV joint seal. 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 11. Repeat this process to remove all six of the balls. 12. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 13. Lift out the cage (4) and the inner race. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4542 14. Remove the inner race (1) from the cage (2) by performing the following steps: 14.1. Rotate the inner race (1) 90 degrees to the centerline of the cage (2). 14.2. Rotate the inner race (1) until one of the lands project through a cage window. 14.3. Remove the inner race (1) from the cage (2). 15. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. ^ The inner and outer race assemblies ^ The CV joint cage ^ The chrome alloy balls 16. Dry all the parts. 17. Check the CV joint assembly for unusual wear, cracks, or other damage. 18. Replace any damaged parts. 19. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4543 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4544 12. Pack the CV joint seal (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small seal clamp (2) onto the CV joint seal. 14. Slide the CV joint seal (1) onto the halfshaft bar. 15. Position the small end of the CV joint seal into the joint seal groove (3) on the halfshaft bar. Notice: Refer to Fastener Notice in Service Precautions. 16. Secure the small seal clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Torque the small clamp (1) to 136 Nm (100 ft. lbs.). Check the gap dimension on the clamp ear. 17. Using your hand, pinch the new swage ring (1) into an oval shape. 18. Slide the distorted swage ring (1) over the large diameter of the CV joint seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4545 Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (1) before installation. 19. Slide the CV joint (2) onto the halfshaft bar (1). The retaining snap ring that is inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position. 20. Slide the large diameter of the CV joint seal (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (3). 21. Mount J 36652. 22. Pull on the CV joint (1) to verify engagement. Important: Align the following items during this procedure: ^ The CV joint seal (3) ^ The housing ^ The swage ring (2) 23. Position the CV joint end (outboard end) (1) of the halfshaft bar assembly in the bottom half of J 36652. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replacement > Page 4546 24. Install the top half of J 36652 onto the lower half of J 36652, over the CV joint (1) and the CV joint seal. 25. Align the swage ring and the swage ring clamp. 26. Insert the bolts into J 36652. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Tighten each bolt alternately until both sides of the top half of J 36652 touch the bottom half of J 36652. 27. Loosen the bolts and remove the halfshaft assembly from J 36652. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4560 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4561 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4562 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4566 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 5 Wheel Bearings Diagnosis Step 6 - 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4567 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4568 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 4574 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 4575 Axle Nut: Specifications Axle Shaft Nut 147 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications Fastener Tightening Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Front Propeller Shaft Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Front Propeller Shaft > Page 4582 Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Page 4583 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The Propeller Shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A one piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models which are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. When the design angles are exceeded, the operational life of the joint decreases. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/- Symptoms Propeller Shaft Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4586 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures - Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: ^ Leaks ^ Noises ^ Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Diagnostic Starting Point Vibration Diagnosis and Correction. Visual/Physical Inspection ^ Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Leak at Front Slip Yoke See: Leak at Front Slip Yoke ^ Universal Joint Noise See: Universal Joint Noise ^ Ping, Snap, or Click Noise See: Ping, Snap, or Click Noise ^ Knock or Clunk Noise See: Knock or Clunk Noise ^ Scraping Noise See: Scraping Noise ^ Squeak Noise See: Squeak Noise Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4587 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - Front Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Front Propeller Shaft Replacement - Front Removal Procedure Important: The driveline components in this vehicle are factory system-balanced. System balance provides a smoother running driveline operation. Observe the position of all the driveline components. Accurately mark the relationship of the components before removal. These components include the propeller shafts, the drive axles, the pinion flanges, and the output shafts. All components must be reassembled in the exact relationship to each other as they were before removal. Follow the specifications, the torque values, and any measurements made prior to disassembly in order to maintain the factory system balance. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Accurately reference mark the propeller shaft to the front axle flange. 3. Remove the bolts from the propeller shaft to the front axle. 4. Remove the propeller shaft. Installation Procedure 1. Install the rear of the propeller shaft to the transfer case. 2. Install the propeller shaft to the front axle. Line up the reference marks made previously. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts to the front axle. Tighten the bolts to 45 Nm (33 ft. lbs.). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - Front > Page 4590 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Rear Propeller Shaft Replacement - Rear Removal Procedure Important: The driveline components in this vehicle are factory system-balanced. System balance provides a smoother running driveline operation. Observe the position of all the driveline components. Accurately mark the relationship of the components before removal. These components include the propeller shafts, the drive axles, the pinion flanges, and the output shafts. All components must be reassembled in the exact relationship to each other as they were before removal. Follow the specifications, the torque values, and any measurements made prior to disassembly in order to maintain the factory system balance. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Accurately reference mark the propeller shaft. 3. Remove the bolts from the rear of the pinion flange. 4. Remove the retainers. Important: Do not pound on the original propeller shaft yoke ears. The injection joints may fracture. Never pry or place any tool between a yoke and a universal joint. 5. Remove the yoke and cross assembly. 6. Tape the bearing cups in order to prevent the loss of bearing rollers. 7. Remove the propeller shaft by using the following procedure: 7.1. Slide the propeller shaft forward. 7.2. Lower the propeller shaft and remove under the rear axle. 7.3. Do not allow the universal joint to incline greatly; the joint may fracture. 8. Clean all the parts with a suitable solvent. 9. Inspect the outer diameter of the nylon injected yoke for burrs. Burring damages the transmission seal. 10. Inspect for proper installation and uniform seating of the bearing cups. 11. Inspect the slip yoke splines for wear. 12. Inspect for twisted slip yoke splines or possibly the wrong universal joint. Replace the parts as necessary. Installation Procedure 1. Install the propeller shaft into the transmission. Important: Install a new universal joint whenever a slip joint or companion flange is serviced. 2. Lubricate the slip joint. 3. Install the yoke and cross assembly onto the pinion flange. 4. Align the reference marks on the pinion flange and the propeller shaft rear yoke. Seat the yoke properly. 5. Install the retainers. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - Front > Page 4591 6. Install the bolts into the pinion flange. Tighten the bolts to 36 Nm (27 ft. lbs.). 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 4592 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Removal Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Remove the propeller shaft. 2. Support the propeller shaft in a line horizontal with the table of a press. 3. Mark the propeller shaft in order to show which end connects to the transmission or transfer case and which end connects to the rear or front axle. 4. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 5. In order to shear the plastic retaining ring on the bearing cup, place the J 9522-3 on the on the open horizontal bearing cups and press the lower bearing cup out of the yoke ear. 6. If the bearing cup is not completely removed, lift the cross, and insert J 9522-5 between the seal and bearing cup being removed. Continue pressing the bearing cup out of the yoke. 7. Rotate the propeller shaft and press the opposite bearing cup out of the yoke. 8. Disassemble the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 4597 10. If you are replacing the front universal joint (rear axle only), remove the bearing cups in the slip yoke in the same manner. 11. Inspect the retaining ring grooves for plastic. 12. Inspect the bearing cup bores for burrs or imperfections. 13. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 14. The sheared plastic may prevent the bearing cups from being pressed into place and thus prevent the bearing retainers from being properly seated. Installation Procedure 1. Remove the bearing cups from the new universal joint journals. 2. Coat the needle bearings in the bearing cups with a thin layer of chassis grease. Use your finger to apply the grease. 3. Install one bearing cup part way into one side of the yoke. 4. Turn the yoke ear towards the bottom. 5. Install the cross into the yoke so that the trunnion seats freely into the bearing cup. 6. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until it is flush with the yoke ear. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 4598 7. Install the opposite bearing cup part way into the yoke ear. Make sure that the trunnions are started straight and true into both bearing cups. Important: If the bearing cup seems to bind or hang-up, stop pressing. Check the needle bearings for misalignment in the bearing cup. 8. Press the opposite bearing cup into the yoke ear. ^ Work the cross all the time. ^ Check for free unbinding movement of the trunnions in the bearing cups. ^ Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. 9. Install the bearing retainer in the retainer groove. ^ Continue pressing until you can snap both retainers into place. ^ A small amount of chassis grease may help the snap ring seat in the bearing cup groove. 10. It the retainer does not seat, spring the yoke slightly with a firm blow from a dead blow hammer. 11. Install the propeller shaft. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 4599 Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Universal Joint Replacement - External Snap Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Removal Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Remove the propeller shaft. 2. Support the propeller shaft in a line horizontal with the table of a press. 3. Mark the propeller shaft in order to show which end connects to the transmission or transfer case and which end connects to the rear or front axle. 4. Remove the snap rings. ^ Pinch the ends of the snap ring together with a pair of pliers. ^ If a snap ring does not readily snap out of the groove in the yoke, tap the end of the bearing cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 6. Press the lower bearing cup out of the yoke ear. Use the J 9522-3. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 4600 7. If the bearing cup is not completely removed, do the following: 7.1. Lift the cross and insert the J 9522-5 between the seal and the bearing cup. 7.2. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft and press the opposite bearing cup out of the yoke. 9. Remove the cross from the yoke. 10. Remove the remaining universal joint parts from the yoke. 11. If you are replacing the front universal joint (rear axle only), remove the bearing cups in the slip yoke in the same manner. 12. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 13. Inspect the bearing cup bores for burrs or imperfections. Important: Corrosion or dirt may prevent the bearing cup installation and may prohibit the proper seating of the bearing retainers. 14. Clean the retaining ring grooves. Installation Procedure 1. Remove the bearing cups from the new universal joint journals. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 4601 2. Coat the needle bearings in the bearing cups with a thin layer of the grease that is present on the journal. Use your finger to apply the grease. 3. Install one bearing cup part way into one side of the yoke. 4. Turn the yoke ear towards the bottom. 5. Install the cross into the yoke so that the trunnion seats freely into the bearing cup. 6. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until it is flush with the yoke ear. 7. Install the opposite bearing cup part way into the yoke ear. 8. Make sure that the trunnions are started straight and true into both bearing cups. Important: If the bearing cup seems to bind or hang-up, stop pressing. Check the needle bearings for misalignment in the bearing cup. 9. Press the opposite bearing cup into the yoke ear. ^ Work the cross all the time. ^ Check for free unbinding movement of the trunnions in the bearing cups. ^ Press the bearing cup into the yoke until the bearing retainer groove is visible over the top of the bearing cup. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 4602 10. Install the bearing retainer in the retainer groove. ^ Continue pressing until you can snap both retainers into place. ^ A small amount of chassis grease may help the snap ring seat in the bearing cup groove. 11. If the retainer does not seat, spring the yoke slightly with a firm blow from a dead blow hammer. 12. Install the propeller shaft. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Engine/Transmission - Flexplate/Flywheel Replacement Flex Plate: Technical Service Bulletins Engine/Transmission - Flexplate/Flywheel Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-003 Date: February, 2003 INFORMATION Subject: Flywheel/Flexplate Replacement Models: 2003 Passenger Cars and Light Trucks When replacing the starter for any reason, the flywheel/flexplate should be inspected before replacement. The flywheel/flexplate should be turned a full 360 degrees and inspected for missing or broken teeth or signs of starter milling on the sides of the teeth before replacement. No flywheel/flexplate should be replaced without a visual defect. The majority of flywheel/flexplates returned to GM after replacement under warranty show no signs of damage or defect. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Flywheel to Crankshaft Bolts Flex Plate: Specifications Flywheel to Crankshaft Bolts Engine Flywheel Bolt ........................................................................................................................... .................................................. 100 Nm (74 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Flywheel to Crankshaft Bolts > Page 4609 Flex Plate: Specifications Flywheel to Torque Converter Bolts Flywheel to Torque Converter Bolt .......................................................................................................................................................... 63 Nm (46 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4610 Flex Plate: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the transmission assembly. 2. Remove the bolts and the engine flywheel. 3. Clean and inspect all parts. Installation Procedure 1. Install the engine flywheel to the crankshaft. 2. Align the locator hole to the pin. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4611 3. Install the engine flywheel bolts. ^ Tighten the engine flywheel bolts in sequence to 100 Nm (74 ft. lbs.). 4. Install the transmission assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Engine/Transmission - Flexplate/Flywheel Replacement Flywheel: Technical Service Bulletins Engine/Transmission - Flexplate/Flywheel Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-003 Date: February, 2003 INFORMATION Subject: Flywheel/Flexplate Replacement Models: 2003 Passenger Cars and Light Trucks When replacing the starter for any reason, the flywheel/flexplate should be inspected before replacement. The flywheel/flexplate should be turned a full 360 degrees and inspected for missing or broken teeth or signs of starter milling on the sides of the teeth before replacement. No flywheel/flexplate should be replaced without a visual defect. The majority of flywheel/flexplates returned to GM after replacement under warranty show no signs of damage or defect. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics > Page 4620 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 4627 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4628 Control Module: Locations Transfer Case Shift Control Module Transfer Case Shift Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4629 Control Module: Service and Repair Transfer Case Shift Control Module REMOVAL 1. Remove the parking brake assembly mounting bolts only and lay the parking brake assembly aside. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4630 2. Remove the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4631 3. Remove the electrical connectors from the control module. 4. Remove the mounting screws for the control module. 5. Remove the control module from the mounting bracket. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4632 1. Install the control module in the mounting bracket. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct park number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the mounting screws for the control module. 3. Tighten the mounting screws to 6 Nm (53 lb.in). 4. Install the electrical connectors in the control module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4633 5. Install the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4634 6. Install the parking brake assembly. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Part 1 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 4640 Part 2 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4645 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4646 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4647 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4648 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4652 Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4653 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4657 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4658 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4659 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4660 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4661 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4666 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4667 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4668 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4674 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4675 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4676 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 4687 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4688 Control Module: Locations Transfer Case Shift Control Module Transfer Case Shift Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4689 Control Module: Service and Repair Transfer Case Shift Control Module REMOVAL 1. Remove the parking brake assembly mounting bolts only and lay the parking brake assembly aside. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4690 2. Remove the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4691 3. Remove the electrical connectors from the control module. 4. Remove the mounting screws for the control module. 5. Remove the control module from the mounting bracket. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4692 1. Install the control module in the mounting bracket. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct park number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the mounting screws for the control module. 3. Tighten the mounting screws to 6 Nm (53 lb.in). 4. Install the electrical connectors in the control module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4693 5. Install the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4694 6. Install the parking brake assembly. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns Fluid - Transfer Case: Customer Interest Drivetrain - Transfer Case Shudder On Tight Turns Bulletin No.: 99-04-21-005E Date: November 28, 2005 TECHNICAL Subject: Transfer Case Shudder (Flush and Replace Transfer Case Fluid) Models: 1999-2005 Chevrolet Astro (AWD) 1999-2005 GMC Safari (AWD) 1999-2001 Oldsmobile Bravada with All-Wheel Drive (NV 136) Transfer Case (RPO NP4) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 99-04-21-005D (Section 04 - Driveline/Axle). Condition Some customers may comment on a vibration (shudder) during tight turning maneuvers on dry pavement at vehicle speeds less than 8 km/h (5 mph). Cause This condition may be caused by a slip-stick of the clutch plates in the transfer case clutch pack. On 1999 to 2002 models, the preload that is designed into the clutch pack may contribute to the condition. In addition, contamination of the fluid may interfere with the friction modifiers. Correction Flush and replace the transfer case fluid on affected vehicles using the following procedure and the part number listed below. Perform the following diagnosis prior to flushing and replacing the transfer case fluid in order to properly identify the shudder. Diagnosis 1. Verify the shudder in the vehicle. The vehicle needs to be at operating temperature (driven at least 8 km (5 mi) for proper diagnosis. After the vehicle is at operating temperature, drive in a tight circle just short of steering wheel lock, at a speed less than 8 km/h (5 mph) in order to identify the shudder. 2. Identify what rear axle type the vehicle has. ^ If the vehicle has a standard rear axle, then proceed to step 3. ^ If the vehicle has a locking rear axle, remove the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. Drive the vehicle as outlined in step 1. ^ If the shudder goes away, install the front propeller shaft and proceed to step 3. Refer to the Propeller Shaft subsection in the Service Manual. ^ If the shudder does not go away, the locking rear axle may be the cause. Evaluate the condition using diagnostic information in the appropriate Service Manual. ^ Install the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. 3. Flush the transfer case with the blue colored fluid (AUTO-TRAK II) using the procedure and part number listed below. Perform the flush procedure even if the transfer case contains the blue colored AUTO-TRAK II fluid in order to remove any possible contaminants. The AUTO-TRAK II fluid contains an improved friction modifier that should correct the slip-stick condition. Refer to the Transfer Case subsection in the Service Manual for information on draining and filling the transfer case. Flush Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns > Page 4703 Important: Refer to Corporate Bulletin Number 99-04-21-001 dated April 1999, for important information on removing the transfer case drain and fill plugs. 1. Drain the transfer case fluid. 2. Refill the transfer case with 2L (2 qts) of new fluid, P/N 12378508 (Canadian P/N 10953626). 3. After refilling the transfer case, drive the vehicle a minimum of 8 km (5 mi). 4. With the transfer case at operating temperature, drain the transfer case fluid again. 5. Refill the transfer case with new fluid. Important: The vehicle may require approximately 160 km (100 miles) of driving before the condition is completely corrected. 6. If this procedure does not correct the shudder condition, please call the Technical Assistance Center for further instructions and review PIP3012D or newer. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Transfer Case Shudder On Tight Turns Bulletin No.: 99-04-21-005E Date: November 28, 2005 TECHNICAL Subject: Transfer Case Shudder (Flush and Replace Transfer Case Fluid) Models: 1999-2005 Chevrolet Astro (AWD) 1999-2005 GMC Safari (AWD) 1999-2001 Oldsmobile Bravada with All-Wheel Drive (NV 136) Transfer Case (RPO NP4) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 99-04-21-005D (Section 04 - Driveline/Axle). Condition Some customers may comment on a vibration (shudder) during tight turning maneuvers on dry pavement at vehicle speeds less than 8 km/h (5 mph). Cause This condition may be caused by a slip-stick of the clutch plates in the transfer case clutch pack. On 1999 to 2002 models, the preload that is designed into the clutch pack may contribute to the condition. In addition, contamination of the fluid may interfere with the friction modifiers. Correction Flush and replace the transfer case fluid on affected vehicles using the following procedure and the part number listed below. Perform the following diagnosis prior to flushing and replacing the transfer case fluid in order to properly identify the shudder. Diagnosis 1. Verify the shudder in the vehicle. The vehicle needs to be at operating temperature (driven at least 8 km (5 mi) for proper diagnosis. After the vehicle is at operating temperature, drive in a tight circle just short of steering wheel lock, at a speed less than 8 km/h (5 mph) in order to identify the shudder. 2. Identify what rear axle type the vehicle has. ^ If the vehicle has a standard rear axle, then proceed to step 3. ^ If the vehicle has a locking rear axle, remove the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. Drive the vehicle as outlined in step 1. ^ If the shudder goes away, install the front propeller shaft and proceed to step 3. Refer to the Propeller Shaft subsection in the Service Manual. ^ If the shudder does not go away, the locking rear axle may be the cause. Evaluate the condition using diagnostic information in the appropriate Service Manual. ^ Install the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. 3. Flush the transfer case with the blue colored fluid (AUTO-TRAK II) using the procedure and part number listed below. Perform the flush procedure even if the transfer case contains the blue colored AUTO-TRAK II fluid in order to remove any possible contaminants. The AUTO-TRAK II fluid contains an improved friction modifier that should correct the slip-stick condition. Refer to the Transfer Case subsection in the Service Manual for information on draining and filling the transfer case. Flush Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns > Page 4709 Important: Refer to Corporate Bulletin Number 99-04-21-001 dated April 1999, for important information on removing the transfer case drain and fill plugs. 1. Drain the transfer case fluid. 2. Refill the transfer case with 2L (2 qts) of new fluid, P/N 12378508 (Canadian P/N 10953626). 3. After refilling the transfer case, drive the vehicle a minimum of 8 km (5 mi). 4. With the transfer case at operating temperature, drain the transfer case fluid again. 5. Refill the transfer case with new fluid. Important: The vehicle may require approximately 160 km (100 miles) of driving before the condition is completely corrected. 6. If this procedure does not correct the shudder condition, please call the Technical Assistance Center for further instructions and review PIP3012D or newer. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case ...................................................................................................................................... .............................................................. 1.9L (2.0 Qt) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4712 Fluid - Transfer Case: Fluid Type Specifications Transfer Case ............................................................................................................................................................. AutoTrak II Fluid GM P/N 12378508 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - New Transfer Case Output Bearing Tool Output Shaft: Technical Service Bulletins Drivetrain - New Transfer Case Output Bearing Tool File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-007 Date: September, 2002 INFORMATION Subject: Release of New Tool J 45380 - Rear Output Shaft Bushing Remover and Installer Models: 1998-2003 Light Duty Truck Models with AWD or 4WD and any of the following Transfer Case Models: 126, 136, 149, 226, 233, 236, 246, 261 or 263 (Except 261 SHD or 263 SHD) A new tool, J 45380, has been released to remove and install the rear output shaft bearing. The following procedures may be used. Identification Identify the transfer case model as shown in the figure shown. Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Information. 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 3. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Remove the rear output shaft seal. 5. Inspect the rear output shaft bushing for scoring or wear. 6. Remove the rear output shaft bushing using the J 45380. 6.1. Install the finger section of the J 45380 in the front of the bushing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - New Transfer Case Output Bearing Tool > Page 4717 6.2. Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. 6.3. Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing on the finger section of the J 45380. ^ Install the finger section of the J 45380. ^ Position the bushing and the tool to the case. ^ Using a hammer and J 45380, install the bushing. 2. Using the appropriate seal installer, install the rear output shaft seal in the transfer case. 3. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in the Propeller Shaft sub-section of the Service Information. 4. Verify the fluid level. Refer to Transfer Case Fluid Replacement. 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement in the Transfer Case sub-section of the Service Information. 6. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 4723 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4724 Control Module: Locations Transfer Case Shift Control Module Transfer Case Shift Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4725 Control Module: Service and Repair Transfer Case Shift Control Module REMOVAL 1. Remove the parking brake assembly mounting bolts only and lay the parking brake assembly aside. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4726 2. Remove the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4727 3. Remove the electrical connectors from the control module. 4. Remove the mounting screws for the control module. 5. Remove the control module from the mounting bracket. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4728 1. Install the control module in the mounting bracket. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct park number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the mounting screws for the control module. 3. Tighten the mounting screws to 6 Nm (53 lb.in). 4. Install the electrical connectors in the control module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4729 5. Install the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4730 6. Install the parking brake assembly. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns Transfer Case Clutch: Customer Interest Drivetrain - Transfer Case Shudder On Tight Turns Bulletin No.: 99-04-21-005E Date: November 28, 2005 TECHNICAL Subject: Transfer Case Shudder (Flush and Replace Transfer Case Fluid) Models: 1999-2005 Chevrolet Astro (AWD) 1999-2005 GMC Safari (AWD) 1999-2001 Oldsmobile Bravada with All-Wheel Drive (NV 136) Transfer Case (RPO NP4) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 99-04-21-005D (Section 04 - Driveline/Axle). Condition Some customers may comment on a vibration (shudder) during tight turning maneuvers on dry pavement at vehicle speeds less than 8 km/h (5 mph). Cause This condition may be caused by a slip-stick of the clutch plates in the transfer case clutch pack. On 1999 to 2002 models, the preload that is designed into the clutch pack may contribute to the condition. In addition, contamination of the fluid may interfere with the friction modifiers. Correction Flush and replace the transfer case fluid on affected vehicles using the following procedure and the part number listed below. Perform the following diagnosis prior to flushing and replacing the transfer case fluid in order to properly identify the shudder. Diagnosis 1. Verify the shudder in the vehicle. The vehicle needs to be at operating temperature (driven at least 8 km (5 mi) for proper diagnosis. After the vehicle is at operating temperature, drive in a tight circle just short of steering wheel lock, at a speed less than 8 km/h (5 mph) in order to identify the shudder. 2. Identify what rear axle type the vehicle has. ^ If the vehicle has a standard rear axle, then proceed to step 3. ^ If the vehicle has a locking rear axle, remove the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. Drive the vehicle as outlined in step 1. ^ If the shudder goes away, install the front propeller shaft and proceed to step 3. Refer to the Propeller Shaft subsection in the Service Manual. ^ If the shudder does not go away, the locking rear axle may be the cause. Evaluate the condition using diagnostic information in the appropriate Service Manual. ^ Install the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. 3. Flush the transfer case with the blue colored fluid (AUTO-TRAK II) using the procedure and part number listed below. Perform the flush procedure even if the transfer case contains the blue colored AUTO-TRAK II fluid in order to remove any possible contaminants. The AUTO-TRAK II fluid contains an improved friction modifier that should correct the slip-stick condition. Refer to the Transfer Case subsection in the Service Manual for information on draining and filling the transfer case. Flush Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns > Page 4748 Important: Refer to Corporate Bulletin Number 99-04-21-001 dated April 1999, for important information on removing the transfer case drain and fill plugs. 1. Drain the transfer case fluid. 2. Refill the transfer case with 2L (2 qts) of new fluid, P/N 12378508 (Canadian P/N 10953626). 3. After refilling the transfer case, drive the vehicle a minimum of 8 km (5 mi). 4. With the transfer case at operating temperature, drain the transfer case fluid again. 5. Refill the transfer case with new fluid. Important: The vehicle may require approximately 160 km (100 miles) of driving before the condition is completely corrected. 6. If this procedure does not correct the shudder condition, please call the Technical Assistance Center for further instructions and review PIP3012D or newer. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Clutch: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns Transfer Case Clutch: All Technical Service Bulletins Drivetrain - Transfer Case Shudder On Tight Turns Bulletin No.: 99-04-21-005E Date: November 28, 2005 TECHNICAL Subject: Transfer Case Shudder (Flush and Replace Transfer Case Fluid) Models: 1999-2005 Chevrolet Astro (AWD) 1999-2005 GMC Safari (AWD) 1999-2001 Oldsmobile Bravada with All-Wheel Drive (NV 136) Transfer Case (RPO NP4) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 99-04-21-005D (Section 04 - Driveline/Axle). Condition Some customers may comment on a vibration (shudder) during tight turning maneuvers on dry pavement at vehicle speeds less than 8 km/h (5 mph). Cause This condition may be caused by a slip-stick of the clutch plates in the transfer case clutch pack. On 1999 to 2002 models, the preload that is designed into the clutch pack may contribute to the condition. In addition, contamination of the fluid may interfere with the friction modifiers. Correction Flush and replace the transfer case fluid on affected vehicles using the following procedure and the part number listed below. Perform the following diagnosis prior to flushing and replacing the transfer case fluid in order to properly identify the shudder. Diagnosis 1. Verify the shudder in the vehicle. The vehicle needs to be at operating temperature (driven at least 8 km (5 mi) for proper diagnosis. After the vehicle is at operating temperature, drive in a tight circle just short of steering wheel lock, at a speed less than 8 km/h (5 mph) in order to identify the shudder. 2. Identify what rear axle type the vehicle has. ^ If the vehicle has a standard rear axle, then proceed to step 3. ^ If the vehicle has a locking rear axle, remove the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. Drive the vehicle as outlined in step 1. ^ If the shudder goes away, install the front propeller shaft and proceed to step 3. Refer to the Propeller Shaft subsection in the Service Manual. ^ If the shudder does not go away, the locking rear axle may be the cause. Evaluate the condition using diagnostic information in the appropriate Service Manual. ^ Install the front propeller shaft. Refer to the Propeller Shaft subsection in the Service Manual. 3. Flush the transfer case with the blue colored fluid (AUTO-TRAK II) using the procedure and part number listed below. Perform the flush procedure even if the transfer case contains the blue colored AUTO-TRAK II fluid in order to remove any possible contaminants. The AUTO-TRAK II fluid contains an improved friction modifier that should correct the slip-stick condition. Refer to the Transfer Case subsection in the Service Manual for information on draining and filling the transfer case. Flush Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Clutch: > 99-04-21-005E > Nov > 05 > Drivetrain - Transfer Case Shudder On Tight Turns > Page 4754 Important: Refer to Corporate Bulletin Number 99-04-21-001 dated April 1999, for important information on removing the transfer case drain and fill plugs. 1. Drain the transfer case fluid. 2. Refill the transfer case with 2L (2 qts) of new fluid, P/N 12378508 (Canadian P/N 10953626). 3. After refilling the transfer case, drive the vehicle a minimum of 8 km (5 mi). 4. With the transfer case at operating temperature, drain the transfer case fluid again. 5. Refill the transfer case with new fluid. Important: The vehicle may require approximately 160 km (100 miles) of driving before the condition is completely corrected. 6. If this procedure does not correct the shudder condition, please call the Technical Assistance Center for further instructions and review PIP3012D or newer. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Clutch: > 04-04-21-003 > Nov > 04 > Drivetrain - Transfer Case Clutch Shimming Transfer Case Clutch: All Technical Service Bulletins Drivetrain - Transfer Case Clutch Shimming Bulletin No.: 04-04-21-003 Date: November 10, 2004 INFORMATION Subject: Automatic Transfer Case Clutch Plate Shimming - Parts Availability Change Models: 1999-2000 Cadillac Escalade 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Astro Van, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1998-2005 GMC Jimmy 1999 GMC Suburban 1999-2005 GMC Safari Van, Sierra, Yukon, Yukon XL 1998-2001 Oldsmobile Bravada with NV 136/236/246 Automatic Transfer Case (RPO NP4 or NP8) While performing the transfer case clutch shimming procedure found in Service Information (SI), you may find it necessary to replace the clutch pack selective fit shim to obtain the correct clutch pack clearance. The selective fit shims for this repair were previously released as a kit, P/N 12474121, which contained all eight selective fit sizes. Effective immediately, the clutch pack shims will be available individually as listed below. The shim kit, P/N 12474121, will be discontinued and no longer available once current stock has been depleted. Parts Information Parts are currently available from GMSPO. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transfer Case Clutch: > 04-04-21-003 > Nov > 04 > Drivetrain - Transfer Case Clutch Shimming Transfer Case Clutch: All Technical Service Bulletins Drivetrain - Transfer Case Clutch Shimming Bulletin No.: 04-04-21-003 Date: November 10, 2004 INFORMATION Subject: Automatic Transfer Case Clutch Plate Shimming - Parts Availability Change Models: 1999-2000 Cadillac Escalade 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Astro Van, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1998-2005 GMC Jimmy 1999 GMC Suburban 1999-2005 GMC Safari Van, Sierra, Yukon, Yukon XL 1998-2001 Oldsmobile Bravada with NV 136/236/246 Automatic Transfer Case (RPO NP4 or NP8) While performing the transfer case clutch shimming procedure found in Service Information (SI), you may find it necessary to replace the clutch pack selective fit shim to obtain the correct clutch pack clearance. The selective fit shims for this repair were previously released as a kit, P/N 12474121, which contained all eight selective fit sizes. Effective immediately, the clutch pack shims will be available individually as listed below. The shim kit, P/N 12474121, will be discontinued and no longer available once current stock has been depleted. Parts Information Parts are currently available from GMSPO. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4771 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4772 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4773 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4774 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4775 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4776 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4780 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4781 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4782 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4783 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4784 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the A/T shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the A/T shift lock control actuator from the steering column jacket assembly. 6. Remove the AT shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the A/T shift lock control actuator onto the steering column jacket assembly. 2. Connect the A/T shift lock control actuator electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4785 3. Adjust the A/T shift lock control actuator with the shift lever clevis in the neutral position: 3.1. Pull out the tab (1) on the adjuster block side (2) of the AT shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the A/T shift lock control actuator for the following items: 4.1. The AT shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the AT shift lock control actuator if needed. 5. Install the lower steering column trim cover. 6. Enable the SIR system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4791 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4792 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4793 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 4796 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 4797 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4798 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4799 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4800 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4801 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4806 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4807 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Electronic Components > Page 4808 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > (TCC) Solenoid Valve Connector, Wiring Harness Side > Page 4811 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4812 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness Tools Required ^ J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4813 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4814 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4815 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4816 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement Control Module: Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Transfer Case Control Module Replacement > Page 4823 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4824 Control Module: Locations Transfer Case Shift Control Module Transfer Case Shift Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4825 Control Module: Service and Repair Transfer Case Shift Control Module REMOVAL 1. Remove the parking brake assembly mounting bolts only and lay the parking brake assembly aside. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4826 2. Remove the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4827 3. Remove the electrical connectors from the control module. 4. Remove the mounting screws for the control module. 5. Remove the control module from the mounting bracket. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4828 1. Install the control module in the mounting bracket. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct park number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the mounting screws for the control module. 3. Tighten the mounting screws to 6 Nm (53 lb.in). 4. Install the electrical connectors in the control module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4829 5. Install the lower dash panel. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4830 6. Install the parking brake assembly. Refer to See: Brakes and Traction Control/Parking Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Brake Switch - TCC: Locations Part 1 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 4836 Part 2 Of 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4841 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4842 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4843 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4844 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4848 Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Locations > Page 4849 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4853 Transmission Position Switch/Sensor: Adjustments PARK/NEUTRAL POSITION SWITCH ADJUSTMENT Important: The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to See: Service and Repair 1. Apply the parking brake. 2. The engine must start in the P (Park) or N (Neutral) positions only. 3. Check the switch for proper operation. If adjustment is required, proceed as follows: 3.1. Place the transmission range selector in the N (Neutral) position. 3.2. With an assistant in the drivers seat, raise the vehicle. 3.3. Loosen the park/neutral position switch mounting bolts. 3.4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 3.5. Following a successful start, turn the engine OFF. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Tighten bolts securing the switch to the transmission. 5. Tighten bolts to 25 Nm (18 lb.ft). 6. Lower the vehicle. 7. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 8. Replace the park/neutral position switch if proper operation can not be achieved. Refer to See: Service and Repair Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4854 Transmission Position Switch/Sensor: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4855 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4856 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4857 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4862 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4863 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Electronic Components > Page 4864 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4870 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4871 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Electronic Components > Page 4872 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: - The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. - The IPC performs the bulb check. - The IPC detects a loss of class 2 communications with the EBCM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications ABS / Traction Control Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations Electronic Brake Control Module: Component Locations Undercarriage Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 4888 Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 4889 Electronic Brake Control Module: Connector Locations Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 4890 Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4891 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C1 Electronic Brake Control Module (EBCM) C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4892 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the electrical connectors from the EBCM. 3. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (5). 4. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 5. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws (1). Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4893 1. Install EBCM (2) on to the BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the new screws (1) in the EBCM (2). Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM. 4. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the two nuts (4). 5. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 6. Return to Diagnostic System Check - ABS. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Application and ID Brake Pressure Modulator Valve (BPMV) Hydraulic Flow Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Application and ID > Page 4897 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU (1) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the 2 electrical harness connectors from the EBCM. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 3. Disconnect 5 brake lines from the BPMV. 4. Slide the EHCU (1) off of the frame bracket (2). 5. Remove 2 bolts (4) securing the BPMV mounting bracket (3) to the BPMV (5). 6. Disconnect the 2-way ABS pump motor connector. 7. Remove the 4 T-25 Torso bolts (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 8. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 9. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Application and ID > Page 4898 Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) onto BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the 4 EBCM bolts (1). Tighten the 4 bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2-way ABS pump motor connector to the EBCM. 4. Install the BPMV (5) to the BPMV mounting bracket (3) with the 2 bolts (4). 5. Slide the EHCU (1) back onto the frame bracket (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the EHCU (1). Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Connect the 2 electrical harness connectors to the EBCM (1). 8. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the 2 nuts (4). 9. Bleed the brake system. 10. Return to Diagnostic System Check-ABS. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-25-006B > Jan > 06 > Brakes Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-25-006B > Jan > 06 > Brakes Low Speed (Below 5 MPH) ABS Activation > Page 4907 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 4913 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04-05-25-009 > Sep > 04 > ABS - Revised Wheel Speed Sensor Replacement Wheel Speed Sensor: All Technical Service Bulletins ABS - Revised Wheel Speed Sensor Replacement File In Section: 05 - Brakes Bulletin No.: 04-05-25-009 Date: September, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Speed Sensor Replacement Models: 2003-2004 Chevrolet Astro Van 2003-2004 GMC Safari Van This bulletin is being issued to revise the Wheel Speed Sensor Replacement in the Antilock Brake System sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information has been incorporated into the Installation steps of the Wheel Speed Sensor Replacement procedure; it does not replace that procedure. The proper installation of the wheel speed sensor (WSS) is critical to prevent corrosion from beneath the sensor. When installing a new WSS, the mounting surface must be free from any rust of corrosion. It is recommended that once the sensor is removed, the WSS bore should be plugged to prevent debris from falling into the hub. Once the WSS bore is plugged, a wire brush or equivalent should be used to clean the WSS mounting surface on the hub. After the mounting surface is free from all corrosion, apply a thin layer of wheel bearing lubricant, GM P/N 01051344 (in Canada, 993037) to the hub surface and the sensor 0-ring prior to installation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 04-05-25-009 > Sep > 04 > ABS - Revised Wheel Speed Sensor Replacement Wheel Speed Sensor: All Technical Service Bulletins ABS - Revised Wheel Speed Sensor Replacement File In Section: 05 - Brakes Bulletin No.: 04-05-25-009 Date: September, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Speed Sensor Replacement Models: 2003-2004 Chevrolet Astro Van 2003-2004 GMC Safari Van This bulletin is being issued to revise the Wheel Speed Sensor Replacement in the Antilock Brake System sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information has been incorporated into the Installation steps of the Wheel Speed Sensor Replacement procedure; it does not replace that procedure. The proper installation of the wheel speed sensor (WSS) is critical to prevent corrosion from beneath the sensor. When installing a new WSS, the mounting surface must be free from any rust of corrosion. It is recommended that once the sensor is removed, the WSS bore should be plugged to prevent debris from falling into the hub. Once the WSS bore is plugged, a wire brush or equivalent should be used to clean the WSS mounting surface on the hub. After the mounting surface is free from all corrosion, apply a thin layer of wheel bearing lubricant, GM P/N 01051344 (in Canada, 993037) to the hub surface and the sensor 0-ring prior to installation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4923 ABS / Traction Control Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4924 Wheel Speed Sensor (RF & LF) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4925 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - LF Wheel Speed Sensor (WSS) - RF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4926 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (A4WD) Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2). Important: The wheel speed sensor mounts to the hub/bearing assembly. Thoroughly clean around this area in order to prevent any dirt or contaminants from entering the sealed wheel bearing. Failure to do this may lead to premature wheel bearing failure. 4. Remove the Wheel Speed Sensor (WSS) mounting bolt. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 5. Remove the wheel speed sensor (5) from the hub/bearing assembly (4). 6. Remove the WSS cable mounting clip from the knuckle. 7. Remove the WSS cable mounting clip from the upper control arm. 8. Remove the WSS cable mounting clip from the frame attachment point. 9. Remove the WSS cable electrical connector. Installation Procedure 1. Install the WSS (5) into the hub/bearing assembly (4). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the WSS mounting bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4927 Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 3. Install the WSS cable mounting clip to the knuckle. 4. Install the WSS cable mounting clip to the upper control arm. 5. Install the WSS cable mounting clip to the frame attachment point. 6. Connect the WSS cable electrical connector. 7. Install the brake rotor (2). 8. Install the tire and wheel. 9. Return to Diagnostic Starting Point - Antilock Brake System. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Starting Point - Antilock Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications BRAKE FLUID Delco Supreme II .............................................................................................................................................. GM P/N 12377967 (Canadian P/N 992667) - or equivalent DOT-3 brake fluid CAUTION: The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 15. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4933 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Hydraulic Brake System Bleeding-Manual Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II09 GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder; then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 7. Have an assistant slowly depress the brake pedal fully and maintain pedal position. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit; install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 12. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit; install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit; install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 14. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 15. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 17. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 17.1. Inspect the brake system for external leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4934 17.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 18. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 19. If the brake system warning lamp remains illuminated, the hydraulic brake pressure differential switch plunger may have be forced out of position during the bleeding procedure and may need to be reset. Perform the following steps to reset the switch. 19.1. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 19.2. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II - GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 19.3. With the ignition key still ON, with the engine OFF, loosen the bleeder valve. 19.4. Have an assistant slowly depress the brake pedal until the brake system warning lamp turns OFF and maintain pedal position while you tighten the bleeder valve. 19.5. Have the assistant slowly release the brake pedal. 20. If the brake system warning lamp continues to remain illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Hydraulic Brake System Bleeding-Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required - J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 29567 Brake Pressure Bleeder Adapter - J 39177Combination Valve Pressure Bleeding Tool, or equivalent - J 41618 Brake Bleeder Adapter Set Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Remove the cap from the metering valve end of the combination valve, then install the J39177, or equivalent to the metering valve. 6. Using the J39177, depress the shaft of the metering valve to maintain the proper flow of brake fluid to the front wheel hydraulic circuit during the pressure bleeding procedure. 7. Assemble the J 41613 to the J 29567. 8. Install the J 41618 and J 29567 to the brake master cylinder reservoir. 9. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the J 29532, or equivalent, to the J 29567. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4935 11. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 12. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 15. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 17. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 18. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right front hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 20. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 21. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 29567. 22. Remove the J 41618 and J 29567 from the brake master cylinder reservoir. 23. Remove the J39177, or equivalent from the metering valve, then install the cap to the metering valve end of the combination valve. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4936 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Remove the booster pushrod (4) and stoplamp switch (2) from brake pedal (1). 2. Remove the nut from the brake pedal pivot bolt. 3. Remove the brake pedal pivot bolt. 4. Remove the brake pedal (1), spacers and bushings from the vehicle. Installation Procedure 1. Install the brake pedal (1) to the vehicle. 2. Install the through bolt, spacers and bushings to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the nut to the brake pedal pivot bolt. Tighten the nut to 45 Nm (33 ft. lbs.). 4. Install the booster pushrod (4) and the stoplamp switch (2) to the brake pedal (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Brake Warning Indicator: Electrical Diagrams Brake Warning System Diagram Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Page 5029 Brake Warning Indicator: Description and Operation Brake Warning System Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: - The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. - The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. - The EBCM detects an ABS malfunction which disables Dynamic Rear Proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. - The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. - The IPC detects a loss of class 2 communications with the BCM or with the EBCM. Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when the following occurs: - The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. - The EBCM detects a low brake fluid condition and sends a class 2 message to the IPC. - The IPC performs the bulb check. - An ABS-disabling malfunction also disables Dynamic Rear Proportioning (DRP). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Guide Pin Bolt-Front ................................................................................................................ .................................................. 108 Nm (80 ft. lbs.) Caliper Guide Pin Bolt-Rear .............................. ....................................................................................................................................... 42 Nm (31 ft. lbs.) Caliper Mounting Bracket to Backing Plate- Rear ............................................................................................................................... 200 Nm (148 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front-15 series ........................................................................................................................ 175 Nm (129 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement Brake Caliper: Service and Repair Brake Caliper - Replacement Front Brake Caliper Replacement- Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. - Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. - Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. - Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5036 11. Remove the 2 brake caliper mounting bolts. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. 12. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Install the brake caliper to the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the 2 brake caliper mounting bolts. Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5037 Important: Install 2 new copper brake hose gaskets. 4. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Rear Brake Caliper Replacement- Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. - Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. - Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. - Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5038 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the caliper guide pin bolts. 11. Remove the brake caliper from the vehicle. 12. Inspect the caliper assembly. Installation Procedure Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new brake pads. 1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the bottom of the caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in order to protect the pistons and the caliper boots. Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both pistons to release any trapped air. 2. Ensure that the caliper boots are below the level of the face of both pistons. 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts. 4.1. Remove all traces of the original adhesive patch. 4.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 4.3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5039 5. Install the brake caliper mounting bolts. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 6. Tighten the brake caliper guide pin bolts. Tighten the brake caliper guide pin bolts to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. Important: Install 2 new copper brake hose gaskets. 8. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5040 Brake Caliper: Service and Repair Brake Caliper - Overhaul Front Brake Caliper Overhaul - Front Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Disassembly Procedure Caution: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 1. Remove the brake caliper from the vehicle. 2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5041 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if necessary. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all of the parts with filtered un-lubricated compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the brake caliper bleed screw. 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seals and the brake caliper bore seal grooves with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new seals into the brake caliper bore seal grooves. 5. Ensure that the seals are not twisted. 6. Lubricate the brake caliper bores and the pistons with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7. Install the boot and piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure the boot seats properly into the piston groove and into the groove in the brake caliper bore. 7.5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Rear Brake Caliper Overhaul - Rear Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5042 Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Disassembly Procedure Important: Replace all the components included in the repair kits used to service this brake caliper. Lubricate the rubber parts with clean brake fluid to make assembly easier. The torque values specified are for dry, non lubricated fasteners. Perform the service operations on a clean bench free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 2. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5043 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with non lubricated filtered compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the brake caliper bleed screw. Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install the new seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore. 8. Install the brake caliper to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5044 Brake Caliper: Service and Repair Brake Caliper Bracket - Replacement Front Brake Caliper Bracket Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake1ose is still connected. Failure to support the caper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's win or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5045 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. - Remove all traces of the original adhesive patch. - Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. - Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the caliper bracket mounting bolts (2). Tighten the brake caliper bracket to knuckle bolt to 175 Nm (121 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. - Install the inner pad-1 wear indicator. - Install the inner pad-2 wear indicators. 6. Slide the brake pads in until they contact he rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-1 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5046 Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5047 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. - Remove all traces of the original adhesive patch. - Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. - Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the caliper bracket mounting bolts (2). Tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5048 Brake Caliper: Service and Repair Disc Brake Hardware - Replacement Front Disc Brake Hardware Replacement- Front Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5049 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps -7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Disc Brake Hardware Replacement- Rear Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5050 4. Remove the disc brake pads from the brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the brake caliper mounting bracket. 6. Remove the caliper slide pins (5) from the brake caliper mounting bracket (3). 7. Remove the caliper slide pin boots (4) from the brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper mounting bracket bushings and the caliper slide pins with high temperature silicone brake lubricant. 2. Install the caliper slide pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper slide pins (5) to the brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the brake caliper mounting bracket. 5. Install the disc brake pads to the brake caliper mounting bracket. 6. Install the disc brake caliper to the brake caliper mounting bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5051 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads - Replacement Brake Pad: Service and Repair Brake Pads - Replacement Front Brake Pads Replacement- Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. 5. Remove the tire and wheel assembly 6. Inspect the caliper operation. Refer to Brake Caliper, Testing and Inspection. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 7. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 8. Remove the brake pads from the caliper mounting bracket. 9. Remove and discard the anti-rattle clips from the brake caliper mounting bracket. 10. Inspect the caliper and mounting bracket. Installation Procedure 1. Install new anti-rattle clips to the inside ends of the caliper mounting bracket. 2. Install the brake pads to the caliper mounting bracket. 3. Install the brake caliper. 4. Install the tire and wheel assembly. 6. Lower the vehicle. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads - Replacement > Page 5056 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the master cylinder reservoir to the proper level with clean brake fluid. 11. Burnish the brake pads and rotors. Rear Brake Pads Replacement- Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. 5. Remove the tire and wheel assembly. 6. Inspect the caliper operation. 7. Place a c-clamp as shown. Slowly bottom the pistons of the caliper. It may be necessary to reposition the c-clamp to allow both of the pistons to bottom into the caliper bores. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 8. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Inspect the caliper assembly. 10. Remove the brake pads from the brake caliper bracket. 11. Remove and discard the anti-rattle clips from the brake caliper mounting bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads - Replacement > Page 5057 Installation Procedure 1. Install the anti-rattle clips to the brake caliper bracket. 2. Install the brake pads to the brake caliper bracket. 3. Install the brake caliper to the mounting bracket. 4. Install the tire and wheel assembly. 5. Lower the vehicle. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. 10. Burnish the brakes pads and rotors as necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads - Replacement > Page 5058 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5063 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5064 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5065 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5066 WARRANTY INFORMATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5067 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5068 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5069 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5070 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5071 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5072 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5073 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5074 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5075 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5076 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5077 Brake Rotor/Disc: Technical Service Bulletins Brakes - Revised Brake Rotor Thickness Measurement Bulletin No.: 03-05-23-004 Date: October 06, 2003 SERVICE MANUAL UPDATE Subject: Revised Brake Rotor Thickness Measurement Procedure Models: 2003 Chevrolet Astro Van Models 2003 GMC Safari Van Models This bulletin is being issued to revise the Brake Rotor Thickness Measurement procedure in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Caution: Refer to Brake Dust Caution in Cautions and Notices. Brake Rotor Thickness Measurement 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Brake Pads Replacement - Front and/or Brake Pads Replacement - Rear. 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement. 4. Compare the lowest thickness measurement recorded to the following specifications: Specification - Front Brake - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in) - Brake rotor discard thickness 27.50 mm (1.083 in) Specification - Rear Brake Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5078 - Brake rotor minimum allowable thickness after refinishing 19.0 mm (0.748 in) - Brake rotor discard thickness 18.5 mm (0.728 in) 5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished. 7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5079 Brake Rotor/Disc: Specifications Front Brakes Rotor Discard Thickness ..................................................................................................................... .................................................. 27.50 mm (1.083 in) Rotor Minimum Allowable Thickness After Refinish ............................................................................................................................. 28.0 mm (1.102 in) Rotor Thickness-new ........................................................................................................... .................................................................... 29.0 mm (1.142 in) Rotor Maximum Allowable Assembled Lateral Runout .......................................................................................................................... 0.13 mm (0.005 in) Rotor Maximum Allowable Scoring ........................................................................................................................................................ 1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation .................................................................................................................................. 0.025 mm (0.001 in) Rear Brakes Rotor Discard Thickness ..................................................................................................................... .................................................... 18.5 mm (0.728 in) Rotor Minimum Allowable Thickness After Refinish ............................................................................................................................. 19.0 mm (0.748 in) Rotor Thickness-new ........................................................................................................... .................................................................. 20.0 mm (0.787 in) Rotor Maximum Allowable Assembled Lateral Runout ........................................................................................................................... 0.13 mm (0.005 in) Rotor Maximum Allowable Scoring ....................................................................................................................................................... 1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation ................................................................................................................................. 0.025 mm (0.001 in) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Replacement Brake Rotor/Disc: Service and Repair Brake Rotor - Replacement Front Brake Rotor Replacement- Front Tools Required - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Removal Procedure Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Use Goodwrench Brake Parts Cleaner, GM P/N 123777981 (Canadian P/N 10953463), or the equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. 3. Mark the relationship of the rotor to the hub. 4. Remove the 2 brake caliper bracket mounting bolts. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and brake caliper mounting bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Remove the rotor retaining push nuts from the wheel studs (if applicable). 7. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Replacement > Page 5082 8. Remove the rotor. Installation Procedure Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. 3. Align the rotor to its original position on the hub (if applicable) and install the rotor. 4. Install the caliper and caliper mounting bracket assembly. 5. Perform the following procedure before installing the brake caliper bracket mounting bolts. - Remove all traces of the original adhesive patch. - Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. - Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Replacement > Page 5083 6. Install the 2 caliper bracket mounting bolts. Tighten the mounting bolts to 175 Nm (121 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master cylinder reservoir to the proper level with clean brake fluid. Rear Brake Rotor Replacement- Rear Removal Procedure Tools Required - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit 1. Release the park brake. 2. Raise and suitably support the vehicle. 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Remove the brake caliper bracket mounting bolts. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 7. Remove the rotor retaining push nuts from the wheel studs (if applicable). 8. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Replacement > Page 5084 9. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle. Installation Procedure Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 4. Install the caliper and the bracket as an assembly to the vehicle. 5. Perform the following procedure before installing the caliper bracket mounting bolts. - Remove all traces of the original adhesive patch. - Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. - Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 6. Install the caliper bracket mounting bolts. Tighten the brake caliper bracket mounting bolts to 175 Nm (129 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master cylinder reservoir to the proper level with clean brake fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Replacement > Page 5085 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Replacement > Page 5086 Brake Rotor/Disc: Service and Repair Brake Rotor - Refinishing Brake Rotor Refinishing Tools Required - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Important: - The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. - Do not refinish disc brake rotors in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification - Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. - Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive bluing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification - Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled Lateral Runout (LRO) that exceeds the maximum allowable specification. Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled Lateral Runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools Until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 12.1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 12.2. Using moderate pressure, apply the non-directional finish: - If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper - If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 12.3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled Lateral Runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications BRAKE FLUID Delco Supreme II .............................................................................................................................................. GM P/N 12377967 (Canadian P/N 992667) - or equivalent DOT-3 brake fluid CAUTION: The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 15. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5098 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Hydraulic Brake System Bleeding-Manual Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II09 GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder; then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 7. Have an assistant slowly depress the brake pedal fully and maintain pedal position. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit; install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 12. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit; install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit; install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 14. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 15. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 17. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 17.1. Inspect the brake system for external leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5099 17.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 18. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 19. If the brake system warning lamp remains illuminated, the hydraulic brake pressure differential switch plunger may have be forced out of position during the bleeding procedure and may need to be reset. Perform the following steps to reset the switch. 19.1. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 19.2. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II - GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 19.3. With the ignition key still ON, with the engine OFF, loosen the bleeder valve. 19.4. Have an assistant slowly depress the brake pedal until the brake system warning lamp turns OFF and maintain pedal position while you tighten the bleeder valve. 19.5. Have the assistant slowly release the brake pedal. 20. If the brake system warning lamp continues to remain illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Hydraulic Brake System Bleeding-Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required - J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 29567 Brake Pressure Bleeder Adapter - J 39177Combination Valve Pressure Bleeding Tool, or equivalent - J 41618 Brake Bleeder Adapter Set Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Remove the cap from the metering valve end of the combination valve, then install the J39177, or equivalent to the metering valve. 6. Using the J39177, depress the shaft of the metering valve to maintain the proper flow of brake fluid to the front wheel hydraulic circuit during the pressure bleeding procedure. 7. Assemble the J 41613 to the J 29567. 8. Install the J 41618 and J 29567 to the brake master cylinder reservoir. 9. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the J 29532, or equivalent, to the J 29567. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5100 11. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 12. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 15. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 17. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 18. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right front hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 20. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 21. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 29567. 22. Remove the J 41618 and J 29567 from the brake master cylinder reservoir. 23. Remove the J39177, or equivalent from the metering valve, then install the cap to the metering valve end of the combination valve. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5101 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Guide Pin Bolt-Front ................................................................................................................ .................................................. 108 Nm (80 ft. lbs.) Caliper Guide Pin Bolt-Rear .............................. ....................................................................................................................................... 42 Nm (31 ft. lbs.) Caliper Mounting Bracket to Backing Plate- Rear ............................................................................................................................... 200 Nm (148 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front-15 series ........................................................................................................................ 175 Nm (129 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement Brake Caliper: Service and Repair Brake Caliper - Replacement Front Brake Caliper Replacement- Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. - Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. - Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. - Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5107 11. Remove the 2 brake caliper mounting bolts. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. 12. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Install the brake caliper to the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the 2 brake caliper mounting bolts. Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5108 Important: Install 2 new copper brake hose gaskets. 4. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Rear Brake Caliper Replacement- Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. - Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. - Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. - Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5109 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the caliper guide pin bolts. 11. Remove the brake caliper from the vehicle. 12. Inspect the caliper assembly. Installation Procedure Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new brake pads. 1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the bottom of the caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in order to protect the pistons and the caliper boots. Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both pistons to release any trapped air. 2. Ensure that the caliper boots are below the level of the face of both pistons. 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts. 4.1. Remove all traces of the original adhesive patch. 4.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 4.3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5110 5. Install the brake caliper mounting bolts. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 6. Tighten the brake caliper guide pin bolts. Tighten the brake caliper guide pin bolts to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. Important: Install 2 new copper brake hose gaskets. 8. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5111 Brake Caliper: Service and Repair Brake Caliper - Overhaul Front Brake Caliper Overhaul - Front Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Disassembly Procedure Caution: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 1. Remove the brake caliper from the vehicle. 2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5112 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if necessary. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all of the parts with filtered un-lubricated compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the brake caliper bleed screw. 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seals and the brake caliper bore seal grooves with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new seals into the brake caliper bore seal grooves. 5. Ensure that the seals are not twisted. 6. Lubricate the brake caliper bores and the pistons with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7. Install the boot and piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure the boot seats properly into the piston groove and into the groove in the brake caliper bore. 7.5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Rear Brake Caliper Overhaul - Rear Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5113 Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Disassembly Procedure Important: Replace all the components included in the repair kits used to service this brake caliper. Lubricate the rubber parts with clean brake fluid to make assembly easier. The torque values specified are for dry, non lubricated fasteners. Perform the service operations on a clean bench free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. 2. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5114 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with non lubricated filtered compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the brake caliper bleed screw. Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install the new seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and piston. 7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 7.3. Push down the piston to the bottom of the brake caliper bore. 7.4. Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore. 8. Install the brake caliper to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5115 Brake Caliper: Service and Repair Brake Caliper Bracket - Replacement Front Brake Caliper Bracket Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake1ose is still connected. Failure to support the caper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's win or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5116 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. - Remove all traces of the original adhesive patch. - Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. - Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the caliper bracket mounting bolts (2). Tighten the brake caliper bracket to knuckle bolt to 175 Nm (121 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. - Install the inner pad-1 wear indicator. - Install the inner pad-2 wear indicators. 6. Slide the brake pads in until they contact he rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-1 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5117 Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5118 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. - Remove all traces of the original adhesive patch. - Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. - Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the caliper bracket mounting bolts (2). Tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5119 Brake Caliper: Service and Repair Disc Brake Hardware - Replacement Front Disc Brake Hardware Replacement- Front Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5120 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps -7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Rear Disc Brake Hardware Replacement- Rear Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5121 4. Remove the disc brake pads from the brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the brake caliper mounting bracket. 6. Remove the caliper slide pins (5) from the brake caliper mounting bracket (3). 7. Remove the caliper slide pin boots (4) from the brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper mounting bracket bushings and the caliper slide pins with high temperature silicone brake lubricant. 2. Install the caliper slide pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper slide pins (5) to the brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the brake caliper mounting bracket. 5. Install the disc brake pads to the brake caliper mounting bracket. 6. Install the disc brake caliper to the brake caliper mounting bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper - Replacement > Page 5122 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Delco Supreme II .............................................................................................................................................. GM P/N 12377967 (Canadian P/N 992667) - or equivalent DOT-3 brake fluid CAUTION: The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information Brake Fluid Irritant Caution CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: ^ Eye Contact - rinse thoroughly with water. ^ Skin Contact - wash with soap and water. ^ If Ingested - consult a physician immediately. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 5128 Brake Fluid: Vehicle Damage Warnings Brake Fluid Effects on Paint and Electrical Components Notice NOTICE: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces., immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables. use a clean shop cloth to wipe away the fluid. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Component Locations Brake Pressure Differential Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Component Locations > Page 5133 Brake Pressure Differential Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Hose to Caliper Bolt Front ............................................................................................................................................................. 40 Nm (30 ft. lbs.) Brake Hose to Caliper Bolt, Rear ............................................................................................................................................................. 40 Nm (30 ft. lbs.) Brake Pipe Fittings ................................................................................................. .................................................................................. 25 Nm (18 ft. lbs.) Hose Bracket to Frame Bolt .............................................................................................................................................................. .. 12 Nm (106 inch lbs.) Hose Bracket to Rear Axle Bolt .......................................................................................................................................................... 17 Nm (150 inch lbs.) Hose Bracket to Anchor Plate Bolt ........................................................................................................................................................... 25 Nm (18 ft. lbs.) Hose Bracket to Knuckle Bolt ............................................................................................................................................................. 12 Nm (106 inch lbs.) Hose Bracket to Upper Control Arm Bolt ............................................................................................................................................... 9 Nm (80 inch lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 5137 Brake Hose/Line: Service Precautions Brake Pipe Replacement Caution CAUTION: Always use double-walled steel brake pipe when replaceing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and in the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and brake system resulting in personal injury. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement Brake Hose/Line: Service and Repair Brake Pipe - Replacement Brake Pipe Replacement Tools Required - J 45405 Brake Pipe Flaring Kit Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice The brake pipes on this vehicle have a nylon coating covering the steel pipe. When servicing the brake pipes, note the following: - When replacing all or part of the brake pipe, use the same style and outside diameter of brake pipe. - Use fittings of the correct size. - Use only double inverted type flares on the ends. 1. Inspect the section of brake pipe to be replaced. 2. Release the brake pipe to be replaced from the retainers as necessary. 3. Select an appropriate location to section the brake pipe, if necessary. - Allow adequate clearance in order to maneuver the J 45405. - Avoid sectioning the brake pipe at bends or mounting points. - Use the pipe cutting tool in the J 45405. 4. Remove the brake pipe from the vehicle. 5. Select the appropriate size of brake pipe and tube nuts. The brake pipe outside diameter determines brake pipe size. 6. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. Add 3 mm (1/8 inch) for each flare to be created. Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 7. Using the pipe cutter in the J 45405, carefully cut the brake pipe squarely to the measured length. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5140 8. Strip the nylon coating from the brake pipe ends to be flared, if necessary. 9. Select the appropriate blade on the coating stripping tool included in the J 45405 by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. 10. Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. 11. While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the metal surface of the brake pipe. 12. Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the roller ledges of the tool. 13. After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. 14. Loosen the stripping tool thumbwheel and remove the brake pipe. Important: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. 15. Inspect the stripped end of the brake pipe to ensure the proper amount of coating has been removed. - 6 mm (1/4 inch) for pipe outside diameter 4.76 mm (3/16 inch) - 9.5 mm (3/8 inch) for pipe outside diameter 6.35 mm (1/4 inch) 16. Chamfer the inside and outside diameter of the pipe with the de-burring tool. 17. Install the tube nuts on the brake pipe noting their orientation. 18. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5141 19. Loosen the die clamping screw of the J 45405. 20. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw and the counterbores of both dies facing the forming ram. 21. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 22. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 23. Remove the unused die (1). 24. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 25. Firmly hand tighten the clamping screw (2) against the dies. 26. Select the appropriate forming mandrel and place into the forming ram. 27. Rotate the hydraulic fluid control valve clockwise to the closed position. 28. Rotate the body of the J 45405 until it bottoms against the die cage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5142 29. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 30. Rotate the hydraulic fluid control valve counterclockwise to the open position in order to allow the forming ram to retract. 31. Insert the finishing cone into the forming ram. 32. Rotate the body of the J 45405 until it bottoms against the die cage. 33. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 34. Rotate the hydraulic fluid control valve counterclockwise to the open position in order to allow the hydraulic forming ram to retract. 35. Loosen the die clamping screw and remove the dies and pipe. 36. Lightly tap the dies on a bench until the die halves separate. 37. Visually inspect the brake pipe flare for correct shape and size. 38. Using a suitable brake pipe bending tool, shape the new pipe using the removed section of pipe as a template. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5143 Important: When installing the pipe, maintain a clearance of 19 mm (3/4 inch) from all moving or vibrating components. 39. Install the pipe to the vehicle with the appropriate brake pipe unions as required. 40. Secure the brake pipe to the retainers. 41. Bleed the brake system. 42. With the engine running and the brakes applied, inspect the brake pipe flares for leaks. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5144 Brake Hose/Line: Service and Repair Brake Hose - Replacement Front Brake Hose Replacement - Front Removal Procedure Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose end and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to prevent brake fluid loss and contamination. 4. Use a backup wrench on the brake hose fitting end (2), disconnect the brake pipe fitting end (1) from the brake hose (2), then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip (3) from the brake hose mounting bracket. 6. Remove the brake hose bracket bolt (3) from the upper control arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5145 7. Remove the brake hose to caliper bolt from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Important: Install 2 new copper brake hose gaskets. 1. Assemble the 2 new copper brake hose gaskets and the brake hose bolt to the brake hose. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the brake hose to caliper bolt-front, and 2 new washers to the brake caliper. Tighten the bolt to 40 Nm (30 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5146 Important: The brake hose must not be twisted. Make sure the brake hose is not in contact with any suspension component. 3. Install the brake hose bracket bolt (3) and the bracket to the upper control arm. Tighten the bolt to 9 Nm (80 inch lbs.). 4. Install the brake hose into the brake hose bracket. 5. Install the brake hose retaining clip (3). 6. Remove the rubber cap or plug from the brake pipe fitting end. 7. Connect the brake pipe fitting end (1) to the brake hose (2): - Use a backup wrench on the brake hose fitting end (2). - Do not bend the mounting bracket or the brake pipe. Tighten the brake pipe fitting end (1) to 25 Nm (18 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Install the tire and wheel assembly. Important: Ensure that the brake hose does not make contact with any part of the suspension or the tire/wheel assembly. Check the brake hose in extreme right and left turn conditions. If the brake hose makes contact remove the brake hose and correct the condition. 10. Lower the vehicle. Rear (Caliper) Brake Hose Replacement - Rear (Caliper) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5147 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose end and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to prevent brake fluid loss and contamination. 4. Use a backup wrench on the brake hose fitting end (1), disconnect the brake pipe fitting end (3) from the brake hose (1) then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip (2) from the brake hose mounting bracket. 6. Remove the brake hose (1) from the mounting bracket. 7. Remove the brake hose to caliper bolt from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Important: Install 2 new copper brake hose gaskets. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5148 1. Assemble the 2 new copper brake hose gaskets and the brake hose bolt to the brake hose. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the brake hose to caliper bolt-rear, and 2 new washers to the brake caliper. Tighten the bolt to 40 Nm (30 ft. lbs.). Important: The brake hose must not be twisted. Make sure the brake hose is not in contact with any suspension component. 3. Install the brake hose (1) into the mounting bracket. 4. Install the brake hose retaining clip (2). 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting end (3) to the brake hose (1): - Use a backup wrench on the brake hose fitting end (1). - Do not bend the mounting bracket or the brake pipe. Tighten the brake pipe fitting end (3) to 25 Nm (18 ft. lbs.). 7. Bleed the hydraulic brake system. 8. Install the tire and wheel assembly Important: Ensure that the brake hose does not make contact with any part of the suspension or the tire/wheel assembly. If the brake hose makes contact remove the brake hose and correct the condition. 9. Lower the vehicle. Rear (Jounce) Brake Hose Replacement - Rear (Jounce) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5149 See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Raise and support the vehicle. 2. Clean all dirt and foreign material from the brake hose and brake pipe fittings. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting (7) from the brake hose (6), then cap or plug the brake pipe fitting end. 4. Remove the brake hose retaining clip (1) from the hose mounting bracket. 5. Remove the jounce hose (6) from the bracket. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 6. Disconnect the 2 rear brake pipes (2) from the jounce hose (1) on the rear axle and cap or plug the brake pipe fitting ends. 7. Remove the jounce hose (1) retaining bolt from the axle. 8. Remove the brake hose from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe - Replacement > Page 5150 1. Install the rear brake hose Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the jounce hose retaining bolt to the axle. Tighten the bolt to 17 Nm (150 inch lbs.). 3. Remove the caps or plugs from the rear brake pipe (2) and connect the pipes to the jounce hose on the axle. Tighten the fitting to 25 Nm (18 ft. lbs.). Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. 4. With the weight of the vehicle on the suspension, install the brake hose (6) into the bracket. 5. Install the jounce hose retaining clip (1). 6. Remove the rubber cap or plug from the exposed brake pipe fitting end (7). 7. Connect the brake pipe fitting (7) to the brake hose (6): - Use a backup wrench on the hose fitting. - Do not bend the bracket or the pipe. Tighten the fitting to 25 Nm (18 ft. lbs.). 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact, remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair Brake Proportioning/Combination Valve: Service and Repair Combination Valve Replacement Removal Procedure Important: Note the identification code on the combination valve. The new valve must have the same identification number as the old valve. 1. Remove the Master Cylinder. 2. Remove the combination valve electrical connector. 3. Remove the front and the rear brake pipes. 4. Remove the combination valve from the vehicle. Installation Procedure Important: Verify that the replacement combination valve has the same pin punched identification code as the code on the old combination valve. 1. Install the combination valve to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the front and the rear brake pipes to the combination valve. Tighten the brake pipe nuts to 25 Nm (18 ft. lbs.). 3. Connect the combination valve electrical connector. 4. Install the Master Cylinder. Important: Verify that the combination valve metering rod is depressed during bleeding. 5. Bleed the brake system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Application and ID Brake Pressure Modulator Valve (BPMV) Hydraulic Flow Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Application and ID > Page 5157 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU (1) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the 2 electrical harness connectors from the EBCM. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 3. Disconnect 5 brake lines from the BPMV. 4. Slide the EHCU (1) off of the frame bracket (2). 5. Remove 2 bolts (4) securing the BPMV mounting bracket (3) to the BPMV (5). 6. Disconnect the 2-way ABS pump motor connector. 7. Remove the 4 T-25 Torso bolts (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 8. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 9. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Application and ID > Page 5158 Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) onto BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the 4 EBCM bolts (1). Tighten the 4 bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2-way ABS pump motor connector to the EBCM. 4. Install the BPMV (5) to the BPMV mounting bracket (3) with the 2 bolts (4). 5. Slide the EHCU (1) back onto the frame bracket (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the EHCU (1). Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Connect the 2 electrical harness connectors to the EBCM (1). 8. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the 2 nuts (4). 9. Bleed the brake system. 10. Return to Diagnostic System Check-ABS. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Mechanical Specifications Brake Master Cylinder: Mechanical Specifications Master Cylinder Mounting Nuts ........................................................................................................... .................................................... 36 Nm (27 ft. lbs.) Brake Pipe Nuts ................................................ ........................................................................................................................................ 30 Nm (22 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Mechanical Specifications > Page 5163 Brake Master Cylinder: Fluid Type Specifications BRAKE FLUID Delco Supreme II .............................................................................................................................................. GM P/N 12377967 (Canadian P/N 992667) - or equivalent DOT-3 brake fluid CAUTION: The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Brake Master Cylinder: Service and Repair Master Cylinder Master Cylinder - Replacement Master Cylinder Replacement Removal Procedure Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Apply the parking brake and block the wheels. 2. Disconnect the brake pipes from the master cylinder. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Plug the open brake pipe ends. 4. Remove the master cylinder nuts and bolts. 5. Remove the combination valve bracket. 6. Remove the master cylinder from the vehicle. 7. Drain the master cylinder of all brake fluid. Installation Procedure 1. Bench bleed the master cylinder. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder > Page 5166 2. Install the master cylinder to the vehicle. 3. Install the combination valve bracket. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 4. Install the master cylinder bolts and nuts. Tighten the nuts to 36 Nm (27 ft. lbs.). 5. Connect the brake pipes to the master cylinder. Tighten the pipe nuts to 30 Nm (22 ft. lbs.). 6. Bleed the hydraulic brake system. Master Cylinder - Overhaul Master Cylinder Overhaul Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. - Cuts or cracks - Nicks or deformation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder > Page 5167 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Master Cylinder - Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder > Page 5168 Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder > Page 5169 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Master Cylinder Reservoir - Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice, refer to Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Notice 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Master Cylinder Reservoir - Replacement Master Cylinder Reservoir Replacement Disassembly Procedure 1. Remove the master cylinder front he vehicle. 2. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder > Page 5170 3. Carefully tap out the reservoir retaining pins. 4. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 5. Remove the seals from the master cylinder. Assembly Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder > Page 5171 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Install the lubricated seals, make sure they are fully seated. 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully tap the reservoir retaining pins into place to secure the reservoir. 8. Install the diaphragm in the cover. 9. Install the cover on the reservoir. 10. Remove the master cylinder from the vice. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder > Page 5172 11. Install the master cylinder. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Description and Operation Parking Brake Actuator: Description and Operation Park Brake Actuator/Adjuster Uses multiplied input force from apply lever to expand park brake shoe toward the friction surface of the drum-in-hat portion of the rear brake rotor. Threaded park brake actuators are also used to control clearance between the park brake shoe and the friction surface of the drum-in-hat portion of the rear brake rotor. System Operation Park brake apply input force is received by the park brake pedal assembly being depressed, transferred and evenly distributed, through the park brake cables and the park brake cable equalizer, to the left and right park brake apply levers. The park brake apply levers multiply and transfer the apply input force to the park brake actuators which expand the park brake shoe toward the friction surface of the drum-in-hat portion of the rear brake rotor in order to prevent the rotation of the rear tire and wheel assemblies. The park brake release handle assembly releases an applied park brake system when it is pulled reward. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Description and Operation > Page 5181 Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement Removal Procedure Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution 1. Release the park brake. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cables by loosening the nut at the adjuster. 5. Remove the park brake cable from the mounting bracket by depressing the locking tabs. 6. Remove the rear park brake cable from the park brake actuator lever. 7. Remove the rotor. 8. Remove the axle shaft. 9. Remove the park brake shoe. 10. Remove the backing plate bolts. 11. Remove the park brake actuator lever housing from the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. 2. Perform the following procedure before installing the backing plate bolts. 2.1. Remove all traces of the original adhesive patch. 2.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 2.3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Description and Operation > Page 5182 3. Install the backing plate bolts. Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 4. Install the park brake shoe. 5. Install the axle shaft. 6. Adjust the park brake shoe. 7. Install the rotor. 8. Install the rear park brake cable to the park brake actuator lever. 9. Install the park brake cable to the mounting bracket until the locking tabs snap into place. 10. Install the tire and wheel assembly. 11. Remove the safety stands and lower the vehicle. 12. Adjust park brake cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair Parking Brake Backing Plate: Service and Repair Park Brake Cable Mounting Bracket Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. 3. Disconnect the rear cables from the equalizer. 4. Remove the rear cables from the mounting bracket by depressing the retaining tabs and pulling rearward. 5. Remove the cable support bracket bolts. 6. Remove the cable support bracket. Installation Procedure 1. Install the cable support bracket. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the cable support bracket bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the rear cables to the mounting bracket by inserting the cable until all the retaining tabs snap into place. 4. Connect the rear cables to the equalizer. 5. Remove the safety stands and lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Intermediate Cable Threaded Rod Nut ................................................................................................................................................. 3.5 Nm (31 inch lbs.) Cable Support Bracket Bolt - Front .......................................................................................................................................................... 35 Nm (26 ft. lbs.) Cable Support Bracket Bolt - Rear ........................................................................................................................................................... 24 Nm (18 ft. lbs.) Park Brake Cable Guide to Frame Bolt ............................................................................................................................................... 13 Nm (115 inch lbs.) Park Brake Cable to Rear Axle Clip Bolt ................................................................................................................................................. 32 Nm (24 ft. lbs.) Park Brake Cable to Shock Absorber Bracket Bolt .................................................................................................................................. 22 Nm (16 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 5189 Parking Brake Cable: Adjustments Park Brake Cable Adjustment Important: Before you adjust the park brake, verify that the park brake shoes are adjusted to provide a clearance of 0.6604 mm (0.026 inch). 1. Rotate the rear wheels and note the amount of brake and driveline drag. 2. Tighten the adjuster, periodically turning the rear wheels by hand until the drag begins to increase. 3. Lower the vehicle. 4. Fully apply and release the park brake lever to the floor 3 times. 5. Raise the vehicle. 6. Repeat step 2. 7. Loosen the adjuster until the brake drag is the same as noted in step 1. 8. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement Parking Brake Cable: Service and Repair Park Brake Cable Equalizer - Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. Remove the threaded end of the right rear park brake cable from the adjuster. 4. Disconnect the cables from the equalizer. Installation Procedure 1. Connect the rear park brake cables to the equalizer. 2. Install the threaded end of the right rear cable to the adjuster. 3. Remove the safety stands and lower the vehicle. 4. Adjust the park brake system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5192 Parking Brake Cable: Service and Repair Park Brake Cable Guide - Replacement Park Brake Cable Guide Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the park brake cable guide bolt to the frame. Tighten the bolt to 13 Nm (115 inch lbs.). 4. Remove the safety stands and lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5193 Parking Brake Cable: Service and Repair Park Brake Cable - Replacement Front Park Brake Cable Replacement- Front Removal Procedure 1. Release the park brake. 2. Remove the cowl side panel trim. 3. Remove the step trim plate. 4. Remove the park brake pedal. 5. Raise and support the vehicle. 6. Loosen the park brake cable at the adjuster. 7. Remove the front park brake cable from the park brake cable adjuster. 8. Remove the front cable from the pedal assembly. 9. Lower the vehicle. 10. Roll the carpet back to remove the cable and grommet from the body. 11. Remove the cable from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5194 1. Install the cable. 2. Route the cable through the floor pan and engage the grommet. 3. Install the front cable to the pedal assembly. 4. Install the pedal assembly. 5. Roll the carpet into place. 6. Install the step trim plate. 7. Install the cowl side panel trim. 8. Raise the vehicle. 9. Connect the front cable to the park brake cable adjuster. 10. Adjust the park brake system. 11. Remove the safety stands and lower the vehicle. Rear - Left Park Brake Cable Replacement - Left Rear Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle 3. Relieve the tension on the park brake cables by loosening the nut at the adjuster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5195 4. Disconnect the cable at the equalizer. 5. Remove the cable from the mounting bracket by depressing the locking tabs. 6. Remove the cable at the shock absorber bracket by removing the bolt. 7. Remove the cable from the backing plate by depressing the locking tabs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5196 8. Remove the cable from the lever. 9. Remove the cable. Installation Procedure 1. Install the cable taking care to correctly route the cable through the guide and the bracket. 2. Install the cable to the lever. 3. Install the cable to the backing plate by pressing the cable into place until locking tabs snap into place. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 4. Install the cable at the shock absorber bracket and install the bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5197 Tighten the bolt to 22 Nm (16 ft. lbs.). 5. Install the cable to the mounting bracket until the locking tabs snap into place. 6. Connect cable end to the equalizer. 7. Remove the safety stands and lower the vehicle. 8. Adjust the park brake cable. Rear - Right Park Brake Cable Replacement -Right Rear Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. 3. Remove the threaded end of the cable from the adjuster. 4. Remove the cable from the differential clip. 5. Remove the cable from the backing plate by depressing the locking tabs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5198 6. Remove the cable from the lever. 7. Remove the cable. Installation Procedure 1. Install the cable taking care to correctly route the cable through the guide and the bracket. 2. Attach the cable to the lever. 3. Install the cable to the backing plate by pressing the cable into place until locking tabs snap into place. 4. Install the cable to the differential clip. Important: After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Equalizer - Replacement > Page 5199 5. Install the cable to the differential clip. 6. Connect the cable to the equalizer. 7. Install the threaded end of the cable into the adjuster nut. 8. Remove the safety stands and lower the vehicle. 9. Adjust the park brake cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Park Brake Lever Mounting Bolts ........................................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 5203 Parking Brake Lever: Service and Repair Park Brake Release Handle Assembly Replacement Removal Procedure 1. Remove the release handle cable and grommet from the park brake pedal assembly (1). 2. Depress the locking tabs and remove the release handle (5) from the instrument panel. Installation Procedure 1. Install the release handle (5) to the instrument panel. Ensure the locking tabs secure the handle to the instrument panel. 2. Install the release handle grommet and cable to the park brake pedal assembly (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair Park Brake Pedal Assembly Replacement Removal Procedure 1. Release the park brake (5). 2. Raise the vehicle. 3. Loosen the equalizer. 4. Lower the vehicle. 5. Remove the release handle cable and grommet from the park brake pedal assembly. 6. Depress the locking tabs and remove the release handle from the instrument panel. 7. Disconnect the electrical connector from the park brake switch. 8. Remove the bolts (2). 9. Disconnect the park brake cable (3) from the lever (1). The locating tab on the lever must be straightened to release the cable. 10. Depress the locking tabs on the park brake cable housing and remove the cable housing from the pedal assembly. 11. Remove the lever assembly from the vehicle. Installation Procedure 1. Install the park brake cable housing to the park brake pedal assembly. Ensure that the locking tabs secure the housing to the assembly. 2. Connect the park brake cable (3) to the lever assembly. Bend the locating tab over the cable. 3. Install the lever assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 4. Install the bolts (2). Tighten the bolts to 24 Nm (18 ft. lbs.). 5. Connect the connector to the park brake switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 5207 6. Install the release handle to the instrument panel. Ensure the locking tabs secure the handle to the instrument panel. 7. Install the release handle grommet and cable to the park brake pedal assembly. 8. Adjust the park brake.. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations Left Front Interior Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Page 5211 Left Front Interior Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Park Brake Shoe Retaining Clip Kit Parking Brake Shoe: Technical Service Bulletins Brakes - Park Brake Shoe Retaining Clip Kit Bulletin No.: 02-05-26-001C Date: January 19, 2005 INFORMATION Subject: Rear Parking Brake Shoe Retaining Spring Clip Service Kit for Drum-in-Hat (DIH) Equipped Vehicles Models: 2004-2005 Buick Rainier 2002-2005 Cadillac Escalade Models 2002-2005 Chevrolet Avalanche 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Silverado Models 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet SSR, TrailBlazer Models 2003-2005 Chevrolet Astro, Express 1998-2005 GMC Jimmy 1999-2005 GMC Sierra Models 2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes. Supercede: This bulletin is being revised to include additional models and clarify parts usage information. Please discard Corporate Bulletin Number 02-05-26-001B (Section 05 - Brakes). A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3). Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Park Brake Shoe Retaining Clip Kit > Page 5216 Important: The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information. Parts Information Parts are currently available from GMSPO. Warranty Information When removal of the rear brake rotors results in damage to the spring clips on vehicles under warranty, use the labor operation shown in conjunction with one of the kit part numbers listed above. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Park Brake Shoe Retaining Clip Kit > Page 5217 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Page 5218 Parking Brake Shoe: Adjustments Park Brake Shoe Adjustment Tools Required - J 21177-A Drum-to-Brake Shoe Clearance Gage Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Important: The park brake shoes must be adjusted before the park brake cable is adjusted. 1. Raise and support the vehicle. 2. Remove the rotors. 3. Set the J21177-A so that it contacts the inside diameter of the rotor. 4. Position the J21 177-A over the shoe and the lining at the widest point. 5. Turn the adjuster nut until the lining just contacts the J21177-A. 6. Repeat steps 1-3 for the opposite side. 7. The clearance between the park brake shoe and the rotor is 0.6604 mm (0.026 inch). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Page 5219 Parking Brake Shoe: Service and Repair Park Brake Shoe Replacement Caution: Refer to Brake Dust Caution, refer to Service Precautions. See: Service Precautions/Technician Safety Information/Brake Dust Caution Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and the wheel. 3. Relieve the tension on the park brake cables by loosening the nut at the adjuster. 4. Remove the park brake cable from the park brake actuator lever. 5. Remove the rotor. 6. Turn the adjustment screw (1) to the fully home position in the notched adjustment nut. 7. Remove the park brake shoe assembly from the backing plate by removing the tips from the slots and sliding the shoe (2) towards the retaining spring (3) until the shoe disengages from the spring. 8. Remove the park brake shoe assembly from the vehicle by passing the open ends of the shoe over the axle shaft. Installation Procedure 1. Clean the debris and the dust from the park brake components using a clean shop cloth. 2. Align the slots in both the adjusting screw (1) and tappet to be parallel with the backing plate face. 3. Install the park brake shoe assembly to the vehicle by passing the open ends of the shoe over the axle shaft. 4. Position the open ends of the park brake shoe on the actuator and tappet. 5. Slide the park brake shoe (2) down and into position under the retaining spring (3). 6. Inspect the shoe assembly position. The shoe must be central on the backing plate with both tips located in the slots. 7. Adjust the park brake shoe. 8. Install the rotor. 9. Install the park brake cable to the park brake actuator lever. 10. Install the tire and wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Page 5220 11. Remove the safety stands and lower the vehicle. 12. Adjust park brake cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Description and Operation Parking Brake Tensioner: Description and Operation Park Brake Cable Adjuster Removes slack in park brake cables. Park Brake Cable Equalizer Evenly distributes input force to both the left and right park brake units. System Operation Park brake apply input force is received by the park brake pedal assembly being depressed, transferred and evenly distributed, through the park brake cables and the park brake cable equalizer, to the left and right park brake apply levers. The park brake apply levers multiply and transfer the apply input force to the park brake actuators which expand the park brake shoe toward the friction surface of the drum-in-hat portion of the rear brake rotor in order to prevent the rotation of the rear tire and wheel assemblies. The park brake release handle assembly releases an applied park brake system when it is pulled reward. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Left Front Interior Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5227 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5228 Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Specifications Hydraulic Brake Booster: Specifications Power Brake Booster Nuts .................................................................................................................. ..................................................... 36 N.m. (27 lb. ft.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Hydraulic Assist System Diagnosis Hydraulic Brake Booster: Testing and Inspection Hydraulic Assist System Diagnosis Brake Assisted System (Hydraulic Assist) / Steps 1 Through 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Hydraulic Assist System Diagnosis > Page 5235 Brake Assisted System (Hydraulic Assist) / Steps 10 Through 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Hydraulic Assist System Diagnosis > Page 5236 Brake Assisted System (Hydraulic Assist) / Steps 17 Through 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Hydraulic Assist System Diagnosis > Page 5237 Hydraulic Brake Booster: Testing and Inspection Hydraulic Brake Assist System Noise Inspection Hydraulic Brake Assist System Noise Inspection Tools Required - J 28662 Brake Pedal Effort Gage 1. Install the J28662to the brake pedal. 2. Start the engine and allow it to idle. Ensure that the wheels are directed straight ahead. 3. Apply and maintain the brakes with 111 N (25 lb) of force to the brake pedal, as indicated on the J 28662. Observe for noises. 4. Quickly release the brakes. Observe for noises. 5. If chatter and/or a vibration of the brake pedal was apparent during the brake system apply of 111 N (25 lb) of force, the power steering drive belt is probably slipping and would require replacement. 6. If any significant noise was apparent during the quick release of the brakes following the brake system apply of 111 N (25 lb) of force, there is likely a restriction in the hydraulic brake booster power steering return hose and it would require replacement. Important: Do NOT apply 445 N (100 lb) of force or more to the brake system pedal for more than 5 seconds at a time. 7. Apply the brakes with 178 N (40 lb) of force to the brake pedal, as indicated on the J 28662, then gradually increase pedal effort up to 445 N (100 lb) of force for not more than 5 seconds at a time. Observe for noises. 8. Quickly release the brakes. Observe for noises. 9. If a hiss noise was apparent and increased during the brake system increasing apply of 178 - 445 N (40 - 100 lb) of force, the hydraulic brake booster assist system is operating normally from an audible standpoint. 10. If a clunk, chatter, and/or clicking noise was apparent during the quick release of the brakes following the brake system increasing apply of 178 445 N (40 - 100 lb) of force, the hydraulic brake booster assist system is operating normally from an audible standpoint. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 5238 Hydraulic Brake Booster: Service and Repair Hydraulic Brake Booster Replacement Removal Procedure Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. 1. Apply the park brake. 2. Place a drain pan under the hydraulic brake booster and the booster reservoir. 3. Disconnect the reservoir hose from the booster. 4. Disconnect the power steering hoses from the booster. Important: Do not remove the brake pipes from the master cylinder. 5. Remove the master cylinder nuts. 6. Support the master cylinder. 7. Disconnect the pushrod from the brake pedal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 5239 8. Remove the hydraulic booster mounting nuts from the inside of the vehicle. 9. Remove the booster assembly. 10. Remove the gasket. Installation Procedure 1. Install the gasket. 2. Install the booster assembly. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the booster mounting nuts. Tighten the nuts to 36 Nm (27 ft. lbs.). 4. Connect the pushrod to the brake pedal. 5. Install the master cylinder. 6. Install the master cylinder nuts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 5240 Tighten the nuts to 36 Nm (27 ft. lbs.). 7. Connect the power steering hoses to the booster. Tighten the hose fittings to 27 Nm (20 ft. lbs.). 8. Connect the reservoir hose to the booster. 9. Bleed the hydraulic brake booster. 10. Release the parking brake. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair Hydraulic Fluid Accumulator: Service and Repair Hydraulic Brake Booster Accumulator Replacement Tools Required - J 26889 Accumulator Piston Compressor Removal Procedure Caution: The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 inch) diameter hole through the end of the accumulator can, opposite the O-ring. Caution: Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Depress brake pedal at least twenty times to relieve pressure in the accumulator. 2. Remove the master cylinder nuts from the hydraulic booster. 3. Remove the master cylinder and secure away from the hydraulic booster. 4. Remove the hydraulic booster. 5. Place the J 26889 over the end of the accumulator. 6. Install the nut on the stud. 7. Depress the accumulator with a C-clamp. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair > Page 5244 8. Rotate retaining ring (2) until either end of the ring is under the access hole (1). 9. Depress and hold the ring with a small tool inserted into the access hole 10. Remove the accumulator retainer ring (1) using a small hook shaped tool. 11. Release the C-clamp. 12. Remove the nut from the stud. 13. Remove the J 26889. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair > Page 5245 14. Remove the accumulator (2) and O-ring seal (3). Installation Procedure 1. Lubricate all seals and metal friction points with power steering fluid. 2. Install the accumulator (2) and O-ring seal (3). 3. Place the J26889 over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair > Page 5246 6. Install the accumulator retainer ring (2). 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J 26889. 10. Install the hydraulic booster. 11. Install the master cylinder to the hydraulic brake booster. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 12. Install the master cylinder nuts. Tighten the master cylinder nuts to 36 Nm (27 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications ABS / Traction Control Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations Electronic Brake Control Module: Component Locations Undercarriage Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 5253 Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 5254 Electronic Brake Control Module: Connector Locations Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 5255 Electronic Brake Control Module (EBCM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5256 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C1 Electronic Brake Control Module (EBCM) C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5257 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the electrical connectors from the EBCM. 3. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (5). 4. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 5. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws (1). Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5258 1. Install EBCM (2) on to the BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the new screws (1) in the EBCM (2). Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM. 4. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the two nuts (4). 5. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 6. Return to Diagnostic System Check - ABS. See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Component Locations Brake Pressure Differential Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Component Locations > Page 5264 Brake Pressure Differential Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations Left Front Interior Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 5268 Left Front Interior Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Left Front Interior Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5272 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5273 Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 5282 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 5288 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-25-009 > Sep > 04 > ABS - Revised Wheel Speed Sensor Replacement Wheel Speed Sensor: All Technical Service Bulletins ABS - Revised Wheel Speed Sensor Replacement File In Section: 05 - Brakes Bulletin No.: 04-05-25-009 Date: September, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Speed Sensor Replacement Models: 2003-2004 Chevrolet Astro Van 2003-2004 GMC Safari Van This bulletin is being issued to revise the Wheel Speed Sensor Replacement in the Antilock Brake System sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information has been incorporated into the Installation steps of the Wheel Speed Sensor Replacement procedure; it does not replace that procedure. The proper installation of the wheel speed sensor (WSS) is critical to prevent corrosion from beneath the sensor. When installing a new WSS, the mounting surface must be free from any rust of corrosion. It is recommended that once the sensor is removed, the WSS bore should be plugged to prevent debris from falling into the hub. Once the WSS bore is plugged, a wire brush or equivalent should be used to clean the WSS mounting surface on the hub. After the mounting surface is free from all corrosion, apply a thin layer of wheel bearing lubricant, GM P/N 01051344 (in Canada, 993037) to the hub surface and the sensor 0-ring prior to installation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5298 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5299 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5305 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5306 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5307 ABS / Traction Control Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5308 Wheel Speed Sensor (RF & LF) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5309 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - LF Wheel Speed Sensor (WSS) - RF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5310 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (A4WD) Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2). Important: The wheel speed sensor mounts to the hub/bearing assembly. Thoroughly clean around this area in order to prevent any dirt or contaminants from entering the sealed wheel bearing. Failure to do this may lead to premature wheel bearing failure. 4. Remove the Wheel Speed Sensor (WSS) mounting bolt. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 5. Remove the wheel speed sensor (5) from the hub/bearing assembly (4). 6. Remove the WSS cable mounting clip from the knuckle. 7. Remove the WSS cable mounting clip from the upper control arm. 8. Remove the WSS cable mounting clip from the frame attachment point. 9. Remove the WSS cable electrical connector. Installation Procedure 1. Install the WSS (5) into the hub/bearing assembly (4). Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the WSS mounting bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5311 Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 3. Install the WSS cable mounting clip to the knuckle. 4. Install the WSS cable mounting clip to the upper control arm. 5. Install the WSS cable mounting clip to the frame attachment point. 6. Connect the WSS cable electrical connector. 7. Install the brake rotor (2). 8. Install the tire and wheel. 9. Return to Diagnostic Starting Point - Antilock Brake System. See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Starting Point - Antilock Brake System Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5317 Neutral Safety Switch: Description and Operation Park/Neutral Position Switch Description and Operation With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. With the transmission in the PARK position, the contacts in the park/neutral switch are closed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5318 Neutral Safety Switch: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5319 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5320 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5321 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 5326 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 5327 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service Precautions Negative: Service Precautions CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the battery feed at the distributor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Remove the battery ground (negative) cable and bolt from the battery 4.3L. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end. Install the battery ground (negative) cable and bolt to the battery. Tighten Tighten the battery terminal bolt to 15 N.m (11 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5334 Negative: Service and Repair Battery Negative Cable Replacement TOOLS REQUIRED J 39200 Digital Multimeter Excessive resistance caused by poor terminal connections and partial short circuits through worn cable insulation will result in an abnormal voltage drop in the starter cable. Low voltage at the starter will prevent the normal starter operation and cause hard starting. Whenever the battery cables are replaced, use a replacement cable that is the same in the type, the diameter, and the length. Some positive cables have additional feed wires attached to them and some of the negative cables have additional ground leads attached. INSPECTION PROCEDURE CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the battery feed at the distributor. 1. Check the voltage drop between the ground (the battery negative terminal) and the vehicle frame. Place one probe of the J 39200 on the grounded battery post (not on the cable clamp) and the other on the frame. Operate the starter and note the voltage reading. 2. Check the voltage drop between the battery positive terminal and the starter terminal stud with the starter operating. 3. Check the voltage drop between the starter housing and the frame with the starter operating. 4. If the voltage drop in any of the above is more than 0.5 volts, there is excessive resistance in the circuit. In order to eliminate resistance, the cables should be disconnected and the connections should be cleaned. If the cables are frayed or the clamps are corroded, the cables should be replaced. When selecting the new cables, ensure that the new cables are the same length and the same diameter as the original cables being replaced. REMOVAL PROCEDURE 1. Disconnect the battery negative cable bolt from the battery. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the battery negative cable from the engine. 3. Disconnect any additional ground leads attached to the battery negative cable. 4. Remove the battery negative cable. INSTALLATION PROCEDURE 1. For RWD, install the battery negative cable in the same position as the original. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5335 2. For A4WD, install the battery negative cable in the same position as the original. 3. Connect the battery negative cable to the engine. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 40 N.m (29 lb ft). 4. Install the engine harness to the stud. Tighten Tighten the nut to 25 N.m (18 lb ft). 5. Connect the battery negative cable ground lead to the radiator support. Tighten Tighten the stud to 45 N.m (33 lb ft). 6. Connect the battery negative terminal bolt to the battery. Tighten Tighten the bolt to 15 N.m (11 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions Positive: Service Precautions CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the battery feed at the distributor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 5339 Positive: Service and Repair BATTERY POSITIVE CABLE REPLACEMENT TOOLS REQUIRED J 39200 Digital Multimeter Excessive resistance caused by poor terminal connections and partial short circuits through worn cable insulation will result in an abnormal voltage drop in the starter cable. Low voltage at the starter will prevent the normal starter operation and cause hard starting. Whenever the battery cables are replaced, use a replacement cable that is the same in the type, the diameter, and the length. Some positive cables have additional feed wires attached to them and some of the negative cables have additional ground leads attached. INSPECTION PROCEDURE CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the battery feed at the distributor. 1. Check the voltage drop between the ground (the battery negative terminal) and the vehicle frame. Place one probe of the J 39200 on the grounded battery post (not on the cable clamp) and the other on the frame. Operate the starter and note the voltage reading. 2. Check the voltage drop between the battery positive terminal and the starter terminal stud with the starter operating. 3. Check the voltage drop between the starter housing and the frame with the starter operating. 4. If the voltage drop in any of the above is more than 0.5 volts, there is excessive resistance in the circuit. In order to eliminate resistance, the cables should be disconnected and the connections should be cleaned. If the cables are frayed or the clamps are corroded, the cables should be replaced. When selecting the new cables, ensure that the new cables are the same length and the same diameter as the original cables being replaced. REMOVAL PROCEDURE 1. Disconnect the battery positive cable bolt from the battery. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the battery positive cable from the starter motor. 3. Disconnect the additional battery positive cable lead to the electrical convenience center. 4. Remove the battery positive cable. INSTALLATION PROCEDURE 1. For RWD, install the battery positive cable in the same position as the original. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 5340 2. For A4WD, install the battery positive cable in the same position as the original. 3. Connect the battery positive cable to the starter solenoid. NOTE: When installing the positive battery cable to the starter solenoid, the inner nut on the solenoid battery terminal must be tightened before the battery cable and the other leads are installed. Failure to do so will result in the solenoid or the solenoid terminal damage. - Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 9 N.m (80 lb in). 4. Connect the additional battery positive cable lead to the underhood electrical center. Tighten Tighten the nut to 9 N.m (80 lb in). 5. Connect the battery positive terminal bolt to the battery. Tighten Tighten the bolt to 15 N.m (11 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Generator Usage Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Alternator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Generator Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5432 Alternator: Description and Operation The AD-230 generator is non-repairable. They are electrically similar to earlier models. The generator(s) feature the following major components: - The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - A voltage regulator The pulley and the fan cool the slip ring and the frame. The AD stands for Air-cooled Dual internal fan; the 2 is an electrical design designator; the 30 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generator is rated at 105 amperes. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5433 Alternator: Service and Repair GENERATOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the air cleaner assembly. 3. Remove the drive belt. 4. Disconnect the regulator electrical connector. 5. Remove the generator front mounting bolts. 6. Remove the generator rear mounting bolt. 7. Remove the generator output (BAT) terminal nut. 8. Remove the generator. INSTALLATION PROCEDURE 1. Position the generator on the vehicle. 2. Loosely install the mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the generator output (BAT) lead. 4. Loosely install the generator output (BAT) nut. Tighten Tighten the mounting bolts to 50 N.m (37 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5434 - Tighten the generator output (BAT) terminal nut to 10 N.m (89 lb in). 1. Connect the regulator electrical connector. 2. Install the drive belt. 3. Install the air cleaner. 4. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation REGULATOR The voltage regulator controls the field current of the rotor in order to limit system voltage. The regulator switches the current on and off at a rate of 400 cycles per second in order to perform the following functions: Radio noise control - Obtain the correct average current needed for proper system voltage control At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5443 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5444 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5445 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations PARK/NEUTRAL POSITION SWITCH Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5449 Neutral Safety Switch: Description and Operation Park/Neutral Position Switch Description and Operation With the ignition in the ON position, battery positive voltage is supplied to the park/neutral position switch. With the transmission in the PARK position, the contacts in the park/neutral switch are closed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5450 Neutral Safety Switch: Service and Repair PARK/NEUTRAL POSITION SWITCH REPLACEMENT Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the tranmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5451 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5452 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. 6. Tighten the bolts securing the switch to 25 Nm (18 lb.ft). 7. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 8. Connect the electrical connectors to the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5453 9. Install the transmission control lever to the manual shaft with the nut. 10. Tighten the control lever nut to 25 Nm (18 lb.ft). 11. Lower the vehicle. 12. Check the switch for proper opeartion. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Battery Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Starter Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5543 Starter Motor Usage Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5544 Starter Motor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the starter motor mounting bolts. 4. Remove any shims previously used. 5. Lower the starter motor. 6. Disconnect the starter enable relay lead (1), the battery positive cable (2), and the generator output (BAT) lead (3) from the starter solenoid field leads. 7. Remove the starter motor. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5545 1. Connect the starter motor field leads to the starter motor as follows: NOTE: Refer to Fastener Notice in Caution and Notices. 1.1. Loosely install the starter enable relay lead (1) to the starter solenoid terminal. Align the terminal retaining tab to the starter solenoid. 1.2. Loosely install generator output (BAT) lead (3) and the battery positive cable (2) to the solenoid terminal. Align the battery positive cable terminal retaining tab to the starter solenoid. Tighten Tighten the starter enable relay lead nut to 2 N.m (18 lb in). - Tighten the battery positive cable nut to 9 N.m (80 lb in). 1. Install the two starter motor mounting bolts and the shims (if necessary) through the starter to the engine. Tighten Tighten the bolts to 43 N.m (32 lb ft). 2. Lower the vehicle. 3. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Starter Solenoid: Locations Battery Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 5549 Battery Wiring (RWD) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 5550 Battery Wiring (AWD) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Front No. 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 Auxiliary Power Outlet - Front No. 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 Auxiliary Power Outlet - Rear Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Schematics Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Convenience Center > Page 5650 Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Convenience Center > Page 5651 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) Fuse: Application and ID Fuse Block I/P (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5654 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5655 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5656 Fuse: Application and ID Fuse Block I/P (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5657 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5658 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5659 Fuse: Application and ID Fuse Block - Underhood (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5660 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5661 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5662 Fuse: Application and ID Fuse Block - Underhood (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5663 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5664 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5665 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5666 Fuse: Application and ID Fuse Block I/P (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5667 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5668 Application Table Part 2 Fuse Block I/P (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5669 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5670 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5671 Application Table Part 3 Fuse Block - Underhood (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5672 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5673 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5674 Application Table Part 2 Fuse Block - Underhood (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5675 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5676 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5677 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5678 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5679 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5680 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5681 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 5682 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 5687 Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 5688 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Convenience Center C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5691 Convenience Center C3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5692 Convenience Center C4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5693 Convenience Center C5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5694 Convenience Center C6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5695 Convenience Center C8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5696 Convenience Center C9 (Upfitter) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5697 Convenience Center C10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5700 Fuse Block: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5701 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5702 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5703 Fuse Block: Application and ID Fuse Block - Underhood (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5704 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5705 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5706 Fuse Block: Application and ID Fuse Block - Underhood (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5707 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5708 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5709 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5710 Fuse Block: Application and ID Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5711 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5712 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5713 Application Table Part 3 Fuse Block - Underhood (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5714 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5715 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5716 Application Table Part 2 Fuse Block - Underhood (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5717 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5718 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5719 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5720 Application Table Part 4 Fuse Block I/P (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5721 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5722 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5723 Application Table Part 2 Fuse Block I/P (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5724 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5725 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 5726 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REPLACEMENT Additional ground straps are used to connect the body frame to the engine and the transmission. Always connect all ground straps to ensure a good ground path to the battery for all electrical components. Removal Procedure 1. Remove the bolt. 2. Clean the bolt and the mounting surface. Installation Procedure 1. Install the ground lead. 2. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 40 N.m (29 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5734 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5735 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5736 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5737 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5738 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5739 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Page 5740 LH Forward Lamp Ground - G101 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions Grounding Point: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Grounding Point: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5792 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Grounding Point: Electrical Diagrams G100 Ground Distribution Diagram 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Ground Distribution Diagram 2 G102 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 Ground Distribution Diagram 1 G103 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Ground Distribution Diagram 1 G104 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Ground Distribution Diagram 3 G105 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Ground Distribution Diagram 4 G106 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Ground Distribution Diagram 2 G107 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Ground Distribution Diagram 4 G110 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Ground Distribution Diagram 5 (1 Of 2) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Ground Distribution Diagram 5 (2 Of 2) G200-299 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Ground Distribution Diagram 6 G300 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 Ground Distribution Diagram 7 G301 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Ground Distribution Diagram 8 G302 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 Ground Distribution Diagram 2 G303 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Ground Distribution Diagram 8 G400 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Ground Distribution Diagram 8 G401 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 Ground Distribution Diagram 7 G403 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Ground Distribution Diagram 7 G404 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 Ground Distribution Diagram 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 Multiple Junction Connector: Diagrams C100 - C110 C100 (I/P To Engine) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5850 C100 (I/P To Engine) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5851 C100 (I/P To Engine) Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5852 C102 (Forward Lamp To I/P) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5853 C102 (Forward Lamp To I/P) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5854 C104 (Engine To Forward Lamp) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5855 C108 (I/P To Rear Lamp Jumper With RPO Code VE1 Japan) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5856 C109 (I/P To Forward Lamp) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5857 C110 (Engine To Brake Pressure Differential Switch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5858 Multiple Junction Connector: Diagrams C200 - C223 C200 (I/P To Main Body) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5859 C200 (I/P To Main Body) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5860 C201 (Steering Column To I/P) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5861 C201 (Steering Column To I/P) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5862 C201 (Steering Column To I/P) Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5863 C201 (Steering Column To I/P) Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5864 C201 (Steering Column To I/P) Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5865 C202 (I/P To Cig/Aux Power Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5866 C203 (I/P To Liftgate) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5867 C203 (I/P To Liftgate) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5868 C205 (I/P To Right/Passenger Door) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5869 C205 (I/P To Right/Passenger Door) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5870 C212 (Heater Jumper To Heater Body) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5871 C213 (A/C Jumper To A/C Body) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5872 C223 (Upfitter Harness) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5873 Multiple Junction Connector: Diagrams C300 - C333 C300 (I/P To Main Body) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5874 C301 (Left/Driver Door To I/P) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5875 C301 (Left/Driver Door To I/P) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5876 C302 (Body To Overhead Console) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5877 C303 (Body To Overhead Console) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5878 C306 (Power Seat Supply Voltage to LH Power Seat) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5879 C308 (Transfer Case Harness to Transfer Case Extension Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5880 C309 (Transfer Case Harness to Transfer Case Extension Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5881 C310 (Fuel Pump Jumper to Engine) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5882 C314 (Engine to Wheel Speed Sensor Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5883 C333 (Upfitter Harness) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5884 Multiple Junction Connector: Diagrams C401 - C404 C401 (Main Body to Rear Door Jamb Switch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5885 C403 (Rear Lamp Jumper to Rear Lamp Assembly Export w/WX7) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5886 C404 (Main Body To Rear - Dome Lamp) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 5887 Splice Pack SP261 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 5893 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 5894 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 5895 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5898 Relay Box: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5899 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5900 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5901 Relay Box: Application and ID Relay Block #1 And #2 Relay Block No.1 Part 1 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5902 Relay Block No.1 Part 2 Relay Block No.2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5903 Application Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5904 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5905 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5906 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5907 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5908 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5909 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 5914 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 5915 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 5916 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5919 Relay Box: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5920 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5921 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5922 Relay Box: Application and ID Relay Block #1 And #2 Relay Block No.1 Part 1 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5923 Relay Block No.1 Part 2 Relay Block No.2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5924 Application Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5925 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5926 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5927 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5928 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5929 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 5930 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5939 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5940 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5941 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5947 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5948 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5949 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5954 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5955 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5956 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5957 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5958 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5959 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 5964 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5970 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5971 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5972 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5973 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5974 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5975 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 5980 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Front No. 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 Auxiliary Power Outlet - Front No. 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 Auxiliary Power Outlet - Rear Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Schematics Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Convenience Center > Page 6080 Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Convenience Center > Page 6081 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) Fuse: Application and ID Fuse Block I/P (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6084 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6085 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6086 Fuse: Application and ID Fuse Block I/P (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6087 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6088 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6089 Fuse: Application and ID Fuse Block - Underhood (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6090 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6091 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6092 Fuse: Application and ID Fuse Block - Underhood (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6093 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6094 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6095 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6096 Fuse: Application and ID Fuse Block I/P (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6097 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6098 Application Table Part 2 Fuse Block I/P (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6099 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6100 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6101 Application Table Part 3 Fuse Block - Underhood (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6102 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6103 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6104 Application Table Part 2 Fuse Block - Underhood (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6105 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6106 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6107 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6108 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6109 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6110 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6111 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6112 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 6117 Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 6118 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Convenience Center C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6121 Convenience Center C3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6122 Convenience Center C4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6123 Convenience Center C5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6124 Convenience Center C6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6125 Convenience Center C8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6126 Convenience Center C9 (Upfitter) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6127 Convenience Center C10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6130 Fuse Block: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6131 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6132 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6133 Fuse Block: Application and ID Fuse Block - Underhood (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6134 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6135 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6136 Fuse Block: Application and ID Fuse Block - Underhood (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6137 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6138 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6139 Application Table Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6140 Fuse Block: Application and ID Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6141 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6142 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6143 Application Table Part 3 Fuse Block - Underhood (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6144 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6145 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6146 Application Table Part 2 Fuse Block - Underhood (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6147 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6148 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6149 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6150 Application Table Part 4 Fuse Block I/P (Front View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6151 Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6152 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6153 Application Table Part 2 Fuse Block I/P (Rear View) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6154 Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6155 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Convenience Center (Front View) > Page 6156 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REPLACEMENT Additional ground straps are used to connect the body frame to the engine and the transmission. Always connect all ground straps to ensure a good ground path to the battery for all electrical components. Removal Procedure 1. Remove the bolt. 2. Clean the bolt and the mounting surface. Installation Procedure 1. Install the ground lead. 2. Install the bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 40 N.m (29 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6164 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6165 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6166 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6167 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6168 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6169 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Page 6170 LH Forward Lamp Ground - G101 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions Grounding Point: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 Grounding Point: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 Grounding Point: Electrical Diagrams G100 Ground Distribution Diagram 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 Ground Distribution Diagram 2 G102 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 Ground Distribution Diagram 1 G103 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 Ground Distribution Diagram 1 G104 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 Ground Distribution Diagram 3 G105 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 Ground Distribution Diagram 4 G106 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 Ground Distribution Diagram 2 G107 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 Ground Distribution Diagram 4 G110 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 Ground Distribution Diagram 5 (1 Of 2) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 Ground Distribution Diagram 5 (2 Of 2) G200-299 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 Ground Distribution Diagram 6 G300 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 Ground Distribution Diagram 7 G301 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Ground Distribution Diagram 8 G302 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 Ground Distribution Diagram 2 G303 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 Ground Distribution Diagram 8 G400 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6272 Ground Distribution Diagram 8 G401 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6273 Ground Distribution Diagram 7 G403 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6274 Ground Distribution Diagram 7 G404 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 6275 Ground Distribution Diagram 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 Multiple Junction Connector: Diagrams C100 - C110 C100 (I/P To Engine) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6280 C100 (I/P To Engine) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6281 C100 (I/P To Engine) Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6282 C102 (Forward Lamp To I/P) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6283 C102 (Forward Lamp To I/P) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6284 C104 (Engine To Forward Lamp) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6285 C108 (I/P To Rear Lamp Jumper With RPO Code VE1 Japan) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6286 C109 (I/P To Forward Lamp) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6287 C110 (Engine To Brake Pressure Differential Switch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6288 Multiple Junction Connector: Diagrams C200 - C223 C200 (I/P To Main Body) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6289 C200 (I/P To Main Body) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6290 C201 (Steering Column To I/P) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6291 C201 (Steering Column To I/P) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6292 C201 (Steering Column To I/P) Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6293 C201 (Steering Column To I/P) Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6294 C201 (Steering Column To I/P) Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6295 C202 (I/P To Cig/Aux Power Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6296 C203 (I/P To Liftgate) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6297 C203 (I/P To Liftgate) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6298 C205 (I/P To Right/Passenger Door) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6299 C205 (I/P To Right/Passenger Door) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6300 C212 (Heater Jumper To Heater Body) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6301 C213 (A/C Jumper To A/C Body) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6302 C223 (Upfitter Harness) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6303 Multiple Junction Connector: Diagrams C300 - C333 C300 (I/P To Main Body) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6304 C301 (Left/Driver Door To I/P) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6305 C301 (Left/Driver Door To I/P) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6306 C302 (Body To Overhead Console) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6307 C303 (Body To Overhead Console) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6308 C306 (Power Seat Supply Voltage to LH Power Seat) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6309 C308 (Transfer Case Harness to Transfer Case Extension Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6310 C309 (Transfer Case Harness to Transfer Case Extension Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6311 C310 (Fuel Pump Jumper to Engine) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6312 C314 (Engine to Wheel Speed Sensor Jumper) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6313 C333 (Upfitter Harness) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6314 Multiple Junction Connector: Diagrams C401 - C404 C401 (Main Body to Rear Door Jamb Switch) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6315 C403 (Rear Lamp Jumper to Rear Lamp Assembly Export w/WX7) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6316 C404 (Main Body To Rear - Dome Lamp) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6317 Splice Pack SP261 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 6323 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 6324 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 6325 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6328 Relay Box: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6329 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6330 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6331 Relay Box: Application and ID Relay Block #1 And #2 Relay Block No.1 Part 1 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6332 Relay Block No.1 Part 2 Relay Block No.2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6333 Application Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6334 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6335 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6336 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6337 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6338 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6339 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 6344 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 6345 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Convenience Center > Page 6346 Fuse Block - Underhood Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6349 Relay Box: Application and ID Convenience Center (Rear View) Location View Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6350 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6351 Application Table Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6352 Relay Box: Application and ID Relay Block #1 And #2 Relay Block No.1 Part 1 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6353 Relay Block No.1 Part 2 Relay Block No.2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6354 Application Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6355 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6356 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6357 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6358 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6359 Application Table Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Convenience Center (Front View) > Page 6360 Application Table Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6369 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6370 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6371 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6377 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6378 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6379 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6384 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6385 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6386 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6387 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6388 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6389 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6394 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6400 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6401 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6402 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6403 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6404 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6405 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6410 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6416 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6417 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6418 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6419 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6420 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6421 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6422 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications Alignment: Specifications Camber Service Allowed -1.0 to +1.0 Service Preferred 0 Cross Camber (L-R) Service Allowed -0.5 to +0.5 Service Preferred 0 Caster-Left Wheel Service Allowed 2.50 to 4.50 Service Preferred 3.5 Caster-Right Wheel Service Allowed 3.50 to 5.50 Service Preferred 4.5 Cross Caster (L-R) Service Allowed -1.5 to -0.5 Service Preferred -1.0 Steering Wheel Angle Service Allowed -6.0 to + 4.0 Service Preferred -1.0 Toe (total) Service Allowed -0.20 to + 0.20 Service Preferred 0 Z Trim Height Service Allowed 5.16 to 5.64 in Service Preferred 5.40 in D Trim Height Service Allowed 5.31 to 5.71 in Service Preferred 5.50 in Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 6425 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6426 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6427 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: Tire construction - Uneven brake adjustment - Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6428 causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Remove alignment rack floating plate pins. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. 1. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and lowest measurements. Z Height Adjustment 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6431 the nut, increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage D Height Measurement The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle D heights should be within 10 mm (0.39 inch) to be considered correct. 1. Place hand on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 3. Allow the vehicle to settle into position. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. 4. Measure the D height by measuring the distance between the rear axle tube or rear axle bracket on vehicles with 7300 GVW rating and the frame. 5. Repeat the jouncing operation 2 more times for a total of 3 times. 6. Use the highest and lowest measurements to calculate the average height. 7. The true D height dimension is the average of the highest and the lowest measurements. 8. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear leaf springs. ^ Worn rear suspension components, such as leaf spring bushings. ^ Collision damage Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6432 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: Inspect the tires for the proper inflation and irregular tire wear. - Inspect the runout of the wheels and the tires. - Inspect the wheel bearings for backlash and excessive play. - Inspect the ball joints and tie rod ends for looseness or wear. - Inspect the control arms and stabilizer shaft for looseness or wear. - Inspect the steering gear for looseness at the frame. - Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. - Inspect the vehicle trim height. - Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. - Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6433 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and the camber angles, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - When checking the left and the right side caster, the right side minus the left side must be equal within 0 degrees to 2.0 degrees. - When setting the left and the right side caster, the right side minus the left side must be equal within 0.50 degrees to 1.50 degrees. - When checking the camber, it must be equal within 1.0 degrees. - When setting the camber, it must be equal within 0.50 degrees. - The caster and the camber set is relative to the ground. Important: When this camber adjustment is followed, the caster setting will not be affected. 1. If the camber is not within specifications, adjust the camber using the following procedure: 1.1. Hold the cam bolt (6) and loosen the nut (2). 1.2. Rotate the cam (1) by rotating the bolt head (6). Turn the cam bolt in order to obtain change equal to 4/2 of the needed correction. 1.3. Hold the cam bolt (6) in this position in order to maintain the setting. 1.4. Obtain the remaining 1/2 of the needed correction by repeating steps 1 through 3 to the other cam bolt. Turn the cam lobe in the same direction. 2. If the caster is not within specifications, adjust the caster using the following procedure: 2.1. Note the camber reading. 2.2. Hold the front cam bolt (6) and loosen the nut (2). 2.3. Turn the front cam bolt in order to obtain a change equal to 1/4 of the desired caster change. At the front cam bolt, a positive camber change produces a positive caster change and a negative camber change produces a negative caster change. 2.4. Hold the cam bolt (6) in this position while tightening the nut (2) in order to maintain setting. 2.5. Hold the rear cam bolt (6) and loosen the nut (2). 2.6. In order to return the camber to the setting that you noted earlier, turn the cam bolt (6) by turning the cam lobe (1) in the opposite direction. 2.7. Check the caster setting. Repeat the above procedure if not within specifications Notice: Refer to Fastener Notice in Service Precautions. 2.8. When adjustments are complete, hold the cam bolt (6) head in order to ensure the cam position does not change while tightening the upper control arm mounting nut. - Tighten the upper control arm mounting nut to 140 Nm (103 ft. lbs.). Front Wheel Toe Adjustment Front Toe Adjustment The toe-in can be increased or decreased by changing the length of the tie rods. A threaded sleeve is provided for this purpose. When the tie rods are mounted ahead of the steering knuckle, the tie rods must be modified as follows: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6434 - Decreased in length in order to increase the toe-in. Increased in length in order to decrease the toe-in. Important: When checking and setting the toe-in, the left and right side to be set separately and the steering wheel must be held straight ahead position within 4 - 6 degrees. Before adjusting the toe-in, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Adjust the toe-in with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - For an accurate toe-in reading, do not push or pull on the tires during the alignment process. 1. Set the steering wheel in the straight ahead position. 2. Loosen the clamp bolts at each end of the steering tie rod adjustable sleeves. Important: The tie rod adjuster often becomes rusted in service. 3. If the torque needed to rotate the adjuster tube exceeds 9 Nm (80 inch lbs.), perform the following steps: 3.1. Remove the adjuster tube clamp nuts and the bolts. Discard the nuts and the bolts. 3.2. Apply the penetrating oil between the adjuster tube and the tie rod threads. 3.3. Rotate the adjuster tube until the tube moves freely. 3.4. Install the new bolts and the nuts with the correct part number. The nut must be towards the front of the vehicle. 4. Rotate the inner and the outer tie rod sockets rearward to the limit of the ball stud travel. 5. Turn the tie rod adjusting sleeves to set the toe-in to specifications. Notice: Refer to Fastener Notice in Service Precautions. Important: Before tightening the adjuster tube nuts, do the following: Check the number of threads on each tie rod within the adjuster tube. The tie rod threads within the adjuster tube must be equal to within 3 threads. - Check the relationship of the adjuster tube to the clamp. The adjuster tube slot and the clamp opening must not be in the same position. The position of the adjuster tube clamp must not exceed 30 degrees in either direction. - The adjuster tube clamp must be on the inside of the adjuster tube dimple. 6. Tighten the adjuster tube clamp nuts. - Tighten the adjuster tube clamp nuts to 25 Nm (18 ft. lbs.). The clamp ends may touch when the nuts are tightened to specification. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6435 7. Rotate the tie rod sockets to the centered position. Ensure that the outer socket is square with the stud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications Connecting Rod to Pitman Arm Nut 48 ft. lbs. Connecting Rod to Relay Rod 35 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement Center Link: Service and Repair Connecting Rod Replacement Connecting Rod Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) Removal Procedure Important: Use the proper tool in order to separate all the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the prevailing torque nut (1) from the connecting rod (4) ball stud. Discard the prevailing torque nut (1). 3. Disconnect the connecting rod (4) from the relay rod (2). 4. Remove the prevailing torque nut (1) from the pitman arm (3) ball stud. Discard the prevailing torque nut (1). 5. Disconnect the connecting rod (1) from the pitman arm (3). 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seals for excessive wear. 8. Clean the threads on the ball stud. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Use the J29193 in order to connect the connecting rod to the pitman arm ball stud. Ensure that the seal is on the stud. - Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. Remove the J 29193. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement > Page 6454 2. Install the new prevailing torque nut (1) to the pitman arm (3) ball stud. - Tighten the nut to 62 Nm (48 ft. lbs.). 3. Use the J29193 in order to install the connecting rod (4) ball stud to the relay rod (2). Ensure that the seal is on the stud. - Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 4. Remove the J 29193. 5. Install the new prevailing torque nut (1) to the ball stud. - Tighten the nut to 47 Nm (35 ft. lbs.). 6. Lower the vehicle. 7. Adjust the toe-in. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement > Page 6455 Center Link: Service and Repair Relay Rod Replacement Relay Rod Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) Removal Procedure Important: Use the proper tool in order to separate all ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the inner tie rod to relay rod retaining nuts. 3. Disconnect the inner tie rods (2) from the relay rod (3). Discard the prevailing torque nut (4). 4. Remove the prevailing torque nut (4) from the connecting rod (5) ball stud. 5. Disconnect the connecting rod from the relay rod. 6. Remove the prevailing torque nuts (4) from the idler arm (1) ball studs. Discard the prevailing torque nuts (4). 7. Use the J 24319-B in order to remove the relay rod from the idler arms. 8. Inspect the threads on the tie rod for damage. 9. Inspect the ball stud threads for damage. 10. Inspect the ball stud seals for excessive wear. 11. Clean the threads on the ball studs. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Use the J. 29193 in order to install the relay rod to the idler arm ball studs. Ensure that the seal is on the stud. - Tighten the J 29193 54 Nm (40 ft. lbs.) in order to seat the tapers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement > Page 6456 2. Remove the J29193. 3. Install the new prevailing torque nut (4) to the idler arm (1) ball studs. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 4. Use the J29193 in order to install the relay rod to the connecting rod ball stud. Ensure that the seal is on the stud. - Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 5. Remove the J29193. 6. Install the new prevailing torque nut (4) to the connecting rod (5) ball stud. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 7. Use the J29193 in order to install the inner tie rod (5) to the relay rod (7). Ensure that the seal is on the stud. Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 8. Remove the J 29193. 9. Install the new prevailing torque nut (8) to the inner tie rod (5). - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 10. Lower the vehicle. 11. Adjust the toe-in. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Recalls for Front Steering Knuckle: > NHTSA03V328000 > Aug > 03 > Recall 03V328000: Steering Knuckle Replacement Front Steering Knuckle: Recalls Recall 03V328000: Steering Knuckle Replacement DEFECT: Some of these minivans have an interference condition between the lower ball joint rubber boot and the steering knuckle (both left and right sides), which could result in cutting of the boot that is intended to seal the ball joint. If the lower ball joint boot were cut, contamination from the road (salt, dirt, water, etc.) could enter the ball socket area of the ball joint causing the joint to wear out too quickly. The steering knuckle could separate from the lower control arm, dropping down the affected corner of the vehicle. The coil spring would push the control arm down into contact with the ground, creating a drag that would slow the vehicle. The driver could have difficulty in maintaining the directional control of the vehicle. In addition, the affected wheel assembly could separate from the vehicle if forces resulting from the wheel's dragging action were sufficient to fracture the tie rod end and upper ball joint connections. Separation of the wheel assembly would also sever that wheel's hydraulic brake hose, resulting in lost braking performance from the front brake system. Vehicle stopping distance would increase, which could result in a crash. REMEDY: Dealers will replace the steering knuckles. The manufacturer has reported that owner notification is expected to begin during the first quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438, or GMC at 1-866-996-9463. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > NHTSA03V328000 > Aug > 03 > Recall 03V328000: Steering Knuckle Replacement Front Steering Knuckle: All Technical Service Bulletins Recall 03V328000: Steering Knuckle Replacement DEFECT: Some of these minivans have an interference condition between the lower ball joint rubber boot and the steering knuckle (both left and right sides), which could result in cutting of the boot that is intended to seal the ball joint. If the lower ball joint boot were cut, contamination from the road (salt, dirt, water, etc.) could enter the ball socket area of the ball joint causing the joint to wear out too quickly. The steering knuckle could separate from the lower control arm, dropping down the affected corner of the vehicle. The coil spring would push the control arm down into contact with the ground, creating a drag that would slow the vehicle. The driver could have difficulty in maintaining the directional control of the vehicle. In addition, the affected wheel assembly could separate from the vehicle if forces resulting from the wheel's dragging action were sufficient to fracture the tie rod end and upper ball joint connections. Separation of the wheel assembly would also sever that wheel's hydraulic brake hose, resulting in lost braking performance from the front brake system. Vehicle stopping distance would increase, which could result in a crash. REMEDY: Dealers will replace the steering knuckles. The manufacturer has reported that owner notification is expected to begin during the first quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438, or GMC at 1-866-996-9463. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6470 Front Steering Knuckle: Specifications Steering Knuckle to Tie Rod End Nut 36 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6471 Front Steering Knuckle: Service and Repair Steering Knuckle Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 36607 Ball Joint Separator - J 36605 Steering Knuckle Seal Installer Removal Procedure Caution: Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Unload the torsion bar. 4. Remove the wheel hub and bearing. 5. Remove the outer tie rod cotter pin and retaining nut. 6. Remove the outer tie rod from the steering knuckle using J 24319-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6472 7. Remove the upper ball joint cotter pin and retaining nut. 8. Install the J 36607 to the upper ball joint and the steering knuckle. 9. Disconnect the upper ball joint from the steering knuckle using the J 36607. 10. Remove the lower ball joint cotter pin and retaining nut. 11. Using a pry bar, placed on top of the upper control arm and on the bottom of the frame, pry downward. 12. With the aid of a helper, carefully hammer on the steering knuckle in the area of the lower ball joint stud in order to release the stud from the steering knuckle. 13. Place a pry bar on the top of the upper control arm and on the bottom of the frame, and pry downward. 14. With the aid of an assistant, carefully hammer on the steering knuckle in the area of the lower ball joint stud in order to release the stud from the steering knuckle. 15. Remove the steering knuckle. 16. Remove the seal from the steering knuckle. Installation Procedure 1. Install the seal into the steering knuckle using the J 36605. 2. Install the steering knuckle to the upper and lower ball joints. 3. Install the lower ball joint to steering knuckle retaining nut. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper ball joint to steering knuckle retaining nut. - Tighten the lower ball joint retaining nut to 128 Nm (95 ft. lbs.). - Tighten the upper ball joint retaining nut to 98 Nm (72 ft. lbs.). 5. Install the new cotter pins. Tighten the nuts up to an additional 1/6 amount in order to insert the cotter pin through the upper and lower ball joint studs. Bend the cotter pin ends flat against the nut. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6473 6. Install the outer tie rod ball stud to the steering knuckle. 7. Install the outer tie rod ball stud retaining nut. - Tighten the outer tie rod ball retaining nut to 49 Nm (36 ft. lbs.). 8. Install a new cotter pin to the outer tie rod stud nut. Bend the pin ends against the nut flats. 9. Install the hub and bearing assembly. 10. Load the torsion bar. 11. Install the tire and wheel. 12. Lower the vehicle. 13. Check the front wheel alignment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications Idler Arm to Frame Bolts 77 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6477 Idler Arm: Service and Repair Idler Arm Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) Removal Procedure Use the proper tool in order to separate ail of the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the bolts (2) from the idler arm (1). 3. Remove the prevailing torque nut (5) from the idler arm (1) ball stud. Discard the prevailing torque nut (5). 4. Use the J24319-B in order to remove the relay rod (4) from the idler arm (5). 5. Remove the idler arm (5). 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seal for cuts or other damage. 8. Clean the threads on the ball stud and in the ball stud nut. Installation Procedure 1. Install the idler arm (1) to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2). - Tighten the bolts to 105 Nm (77 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6478 3. Use the J29193 in order to install the relay rod to the idler arm ball stud. Ensure that the seal is on the stud. Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 4. Remove the J29193. 5. Install the new prevailing torque nut to the idler arm (5) ball stud. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 6. Lower the vehicle. 7. Adjust the toe-in. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications Pitman Arm: Specifications Pitman Arm to Steering Gear Nut 184 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 6482 Pitman Arm: Service and Repair Pitman Arm Replacement - Tools Required J 29107-A Pitman Arm Puller Removal Procedure Important: Use the proper tool in order to separate all of the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the power steering gear. 4. Remove the pitman arm retaining nut and washer. Mark the pitman arm and the pitman shaft in order to permit proper alignment during assembly. Notice: Do not hammer on the pitman arm, pitman arm shaft or puller. Damage to the pitman arm or steering gear may result. 5. Use the J29107-A in order to remove the pitman arm. 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seals for excessive wear. 8. Clean the threads on the ball stud and the ball stud nut. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 6483 1. Align the marks made on the pitman arm during removal in order to install the pitman arm on the pitman shaft. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the washer and the pitman arm retaining nut. - Tighten the pitman arm retaining nut to 250 Nm (185 ft. lbs.) 3. Install the power steering gear. 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Bleeding the Power Steering System - Tools Required J 35555 Metal Mity vac - J 43485 Power Steering Bleeder Adapter Important: Hoses touching the frame, body, or engine may cause system noise. 1. Verify that the hoses do not touch any other part of the vehicle. Important: Loose connections may not leak, but could allow air into the steering system. 2. Verify that all hose connections are tight. Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Important: Maintain the fluid level throughout the bleed procedure. 3. Remove the pump reservoir cap. Important: Use clean, new power steering fluid only. 4. Fill the pump reservoir with fluid to the FULL COLD level. 5. Attach the J 43485 to the J 35555 or equivalent. 6. Place the J 43485 on or in the pump reservoir filler neck. 7. Apply a vacuum of 68 kPa (20 in Hg) maximum. 8. Wait 5 minutes. Typical vacuum drop is 7 - 10 kPa (2 - 3 in Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis. 9. Remove the J 43485 and the J 35555. 10. Reinstall the pump reservoir cap. 11. Start the engine. Allow the engine to idle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6488 12. Turn off the engine. 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. Important: Do not turn steering wheel to lock. 14. Start the engine. Allow the engine to idle. 15. Turn the steering wheel 180-360 degrees in both directions 5 times. 16. Switch the ignition off. Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. 17. Verify the fluid level. 18. Remove the pump reservoir cap. 19. Attach the J 43485 to the J 35555 or equivalent. 20. Place the J 43485 on or in the pump reservoir filler neck. 21. Apply a vacuum of 68 kPa (20 in Hg) maximum. 22. Wait 5 minutes. 23. Remove the J 43485 and the J 35555. 24. Verify the fluid level. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6489 25. Reinstall the pump reservoir cap. Excessive Vacuum Drop Diagnosis 1. If the vacuum continues to drop, remove the pressure and return hose from the pump. 2. Install the plugs (1,2) supplied with the J 43485 into the pressure and return port. 3. Attach the J 43485 to the J 35555 or equivalent. 4. Place the J 43485 on or in the pump reservoir filler neck. 5. Apply a vacuum of 68 kPa (20 in Hg) maximum. 6. If the vacuum drops again, repair or replace the pump. If the vacuum holds steady, continue to check the other parts of the steering system. Important: Fluid must be free from bubbles and foam. Be aware of periodic bubbles that indicate a loose connection or leaking O-ring seal in the return hose or the pressure hose. Fluid must be free from discoloration. 7. Observe the fluid. 8. If condition persists, replace the following parts: - The return hose clamps - The return hose O-rings - The pressure hose O-rings Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6490 - The gear cylinder line O-rings - The reservoir to pump O-ring 9. Repeat the bleed procedure from the beginning. 10. Drive the vehicle approximately 16 km (10 mi) in order to warm the system to operating temperature. Evaluate vehicle on a smooth flat surface. 11. Verify the following conditions: - There is smooth power assist. - The vehicle operates quietly. - The pump maintains the proper fluid level. - There is not any leaking in the steering system. - The fluid is free of foam or discoloration. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Fluid Type .......................... GM Power Steering Fluid GM P/N 1052884 - 1 pint (Canadian P/N 993294), 1050017 - 1 quart, (Canadian P/N 992646) or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications Remote Reservoir Mounting Bolts 35 inch lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle Power Steering Fluid Reservoir: Service and Repair Power Steering Reservoir Replacement - Off Vehicle Power Steering Reservoir Replacement -Off Vehicle Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the pump mounting studs (2). 3. Remove the connector and fitting assembly (4). 4. Remove the O-ring seal (3) from the connector and fitting assembly (4). 5. If replacement is required, remove the control valve assembly and the flow control spring from the pump housing assembly. 6. Remove the reservoir assembly (1) from the pump housing assembly (2). 7. Remove the O-ring seals (1), (4) and (5). 8. Remove the magnet (3). 9. Clean the magnet (3). 10. Inspect the Welch plug in the power steering pump housing (2). Do not remove. If the Welch plug is deformed or dislodged, replace the power Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6499 steering pump. Assembly Procedure Important: Use new O-ring seals when assembling the power steering pump assembly. 1. Lubricate the O-ring seals (1), (4) and (5) with power steering fluid. 2. To install the control valve assembly and flow control spring to the pump housing assembly (2); refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle. 3. Install the O-ring seals (1), (4) and (5) to the pump housing assembly (2). 4. Install the magnet (3) to the pump housing assembly (2). 5. Connect the reservoir assembly (1) to the pump housing assembly (2). 6. Install the O-ring seal. 7. Install the connector and fitting assembly (4) to the pump housing (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6500 Notice: Refer to Fastener Notice in Service Precautions. 8. Install the pump mounting studs (2) to the pump housing (1). - Tighten the pump mounting studs (2) to 58 Nm (43 ft. lbs.). - Tighten the connector and fitting assembly (4) to 75 Nm (55 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6501 Power Steering Fluid Reservoir: Service and Repair Remote Power Steering Fluid Reservoir Replacement Remote Power Steering Fluid Reservoir Replacement Removal Procedure 1. Place drain pan under the vehicle. 2. Draw all of the fluid out of the reservoir in order to avoid spills. 3. Disconnect the hydraulic brake booster hose from the power steering reservoir. 4. Disconnect the power steering reservoir to the power steering pump hose from the power steering reservoir. 5. Remove the power steering reservoir mounting bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6502 6. Remove the power steering reservoir. Installation Procedure 1. Install the power steering reservoir. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering reservoir mounting bolts. - Tighten the power steering reservoir mounting bolts to 4 Nm (35 inch lbs.). 3. Connect the power steering reservoir to the power steering pump hose to the power steering reservoir. 4. Connect the hydraulic brake booster hose to the power steering reservoir. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6503 5. Bleed the power steering system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight Power Steering Line/Hose: Customer Interest Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight > Page 6512 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight Power Steering Line/Hose: All Technical Service Bulletins Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight > Page 6518 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 6519 Power Steering Line/Hose: Specifications Power Steering Hose Fittings 20 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement Power Steering Line/Hose: Service and Repair P/S Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement Removal Procedure 1. Disconnect the power steering cooler hose from the steering pump. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Install a drain pan under the vehicle. 4. Disconnect the power steering cooler pipe hose from the steering gear. 5. Remove the power steering cooler pipe (2) from the air baffle (3). 6. Remove the power steering cooler pipe from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6522 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe (2) to the air baffle (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the power steering cooler pipe to the steering gear. - Tighten the power steering cooler pipe to the steering gear to 27 Nm (20 ft. lbs.). 4. Lower the vehicle. 5. Connect the power steering cooler hose to the steering pump. 6. Bleed the power steering system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6523 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the hydraulic brake booster inlet hose from the of the power steering pump. 3. Lower the vehicle. 4. Disconnect the hydraulic brake booster inlet hose from the hydraulic brake booster. 5. Remove the hydraulic brake booster inlet hose from vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6524 1. Install the hydraulic brake booster inlet hose to vehicle. 2. Connect the hydraulic brake booster inlet hose to the hydraulic brake booster. 3. Raise the vehicle. Refer to Vehicle Lifting. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the hydraulic brake booster inlet hose to the power steering pump. - Tighten the hydraulic brake booster inlet hose to the power steering pump to 27 Nm (20 ft. lbs.). 5. Bleed the system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6525 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure Important: Note the position of all the tie-straps, power steering hoses and the hose insulators for proper re-installation. 1. Remove the power brake booster outlet hose tie-straps. 2. Place a drain pan under the vehicle. 3. Disconnect the power steering cooler hose from the power steering gear. 4. Disconnect the hydraulic brake booster outlet hose from the steering gear. 5. Disconnect the hydraulic brake booster outlet hose from the hydraulic brake booster. 6. Remove the hydraulic brake booster outlet hose from the vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6526 1. Install the hydraulic brake booster outlet hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the hydraulic brake booster outlet hose to the hydraulic brake booster. - Tighten the hydraulic brake booster outlet hose to the hydraulic brake booster to 27 Nm (20 ft. lbs.). 3. Connect the hydraulic brake booster outlet hose to the power steering gear. - Tighten the hydraulic brake booster outlet hose to the power steering gear to 27 Nm (20 ft. lbs.). 4. Remove the drain pan. 5. Install the hydraulic brake booster outlet hose tie straps. 6. Bleed the system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications Power Steering Pump Control Valve Fitting 55 ft. lbs. Power Steering Pump Mountings Bolts 37 ft. lbs. Power Steering Pump Mounting Nut 30 ft. lbs. Power Steering Pump Mounting Studs 43 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6534 Power Steering Pump Disassembled View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6535 Power Steering Pump: Testing and Inspection Please see STEERING/TESTING and INSPECTION for information on this component. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Replacement Power Steering Pump Flow Control Valve Replacement - Off Vehicle Disassembly Procedure 1. Drain the oil from the reservoir (1). 2. Remove the connector and fitting assembly (2). 3. Remove the control valve assembly (4) from the pump housing (1). Make sure the flow control spring (5) does not fall out of the pump housing (1). 4. Remove and discard the O-ring seal (3) from the connector and fitting assembly (2). Assembly Procedure 1. Install the flow control spring (5), if removed from the pump housing (1). 2. Lubricate the new O-ring seal (3) with power steering fluid. 3. Install the O-ring seal (3) onto the connector and fitting assembly (2). 4. Install the control valve assembly (4). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the connector and fitting assembly (2). - Tighten the connector and fitting assembly to 75 Nm (55 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6538 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement Power Steering Pulley Replacement - Tools Required J 25034-C Power Steering Pump Pulley Remover - J 25033-C Power Steering Pump Pulley Installer Removal Procedure 1. Remove the lower fan shroud. 2. Remove the drive belt. 3. Remove the power steering pump pulley using the J 25034-C. Installation Procedure 1. Place the power steering pump pulley on the end of the power steering pump shaft. 2. Install the power steering pump pulley using J 25033-C. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6539 3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 inch). 4. Install the drive belt. 5. Install the lower fan shroud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6540 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement Removal Procedure 1. Remove the power steering pump pulley. 2. Place a drain pan under the vehicle. Important: Cap or plug the ends of the power steering hoses to prevent fluid loss. 3. Disconnect the power brake booster inlet hose from the power brake booster. 4. Disconnect the power steering cooler hose from the power steering pump. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6541 5. Disconnect the power steering pump remote reservoir hose from the power steering pump. 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Remove the power steering pump rear mounting bracket nut. 8. Lower the vehicle. 9. Loosen the accessory bracket bolts and nut. Pull the accessory bracket forward. 10. Remove the power steering pump mounting bolts. 11. Remove the power steering pump and the power brake booster inlet hose from the vehicle. 12. Remove the power brake booster inlet hose from the power steering pump. Installation Procedure 1. Install the power brake booster inlet hose to the power steering pump. 2. Install the power steering pump and the power brake booster inlet hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pump mounting bolts. - Tighten the power steering pump mounting bolts to 50 Nm (37 ft. lbs.). 4. Reposition the accessory mounting bracket and tighten the bolts and nut. - Tighten the accessory mounting bracket bolts to 50 Nm (37 ft. lbs.). - Tighten the accessory mounting bracket nut to 41 Nm (30 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6542 5. Raise the vehicle. Refer to Vehicle Lifting. 6. Install the power steering pump rear mounting bracket nut. - Tighten the power steering pump rear mounting bracket nut to 41 Nm (30 ft. lbs.). 7. Lower the vehicle. 8. Uncap the ends of the power steering hoses. 9. Connect the power steering pump remote reservoir hose to the power steering pump. 10. Connect the power steering cooler hose to the power steering pump. 11. Connect the power brake booster inlet hose to the power brake booster. - Tighten the power brake booster inlet hose to the power brake booster to 27 Nm (20 ft. lbs.). 12. Remove the drain pan from under the vehicle. 13. Install the power steering pump pulley. 14. Bleed the power steering system. 15. Inspect the power steering pump for leaks and the hoses for proper clearance from the frame and from other components. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6548 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor connector (1) located on the frame crossmember. 7. Disconnect the inflatable restraint front end discriminating sensor connector. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6549 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6550 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 7. Disconnect the I/P module yellow 2-way connector (1). Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6551 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6552 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connector to the inflatable restraint front end discriminating sensor (1) located on the frame crossmember. 2. Install the CPA to the inflatable restraint front end discriminating sensor connector. 3. Install the AIR BAG fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6553 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6 Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6554 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the passenger knee bolster. 5. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6555 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the passenger knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations > Page 6559 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations > Page 6560 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations > Page 6561 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair Steering Gear Seal: Service and Repair Pitman Shaft Seal Replacement On Vehicle - Tools Required J 4245 Internal Snap Ring Pliers - J 6219 Pitman Shaft Seal Installer Removal Procedure 1. Remove the pitman arm. 2. Remove the snap ring (1) using J 4245. 3. Remove the following components from the power steering gear (1): 3.1. The dust seal (5) 3.2. The return ring (4) 3.3. The washer (3) 3.4. The pitman shaft oil seal (2) 4. Inspect the Pitman shaft surface for roughness or pitting. Replace the pitman shaft if the shaft is pitted. 5. Clean the pitman shaft and seal areas using a wire brush. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Page 6566 1. Lubricate the new seals with grease. 2. Apply a single layer of tape to the pitman shaft in order to avoid damaging the seals. 3. Install the pitman shaft oil seal (2) and washer (3) to the power steering gear. 4. Use the J 6219 to install the pitman shaft seal and washer to the power steering gear. The seal should be in far enough to install the return ring, dust seal, and the snap ring. 5. Install the return ring and the dust seal to the power steering gear. 6. Use J 6219 in order to seat the return ring and the dust seal in the power steering gear. 7. Install the snap ring to the pitman shaft using J 4245. 8. Install the pitman arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Intermediate Shaft to Steering Gear Pinch Bolt 30 ft. lbs. Intermediate Shaft to Steering Column Pinch Bolt 30 ft. lbs. Intermediate Shaft to Steering Gear Pinch Bolt 30 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 6570 Steering Shaft: Service and Repair "For information regarding this component please refer to steering column service and repair" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Steering Wheel Nut 30 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6574 Steering Wheel: Description and Operation STEERING WHEEL AND COLUMN The steering wheel and column are designed to absorb energy when driver contact is made with the steering wheel or inflated air bag. In a frontal collision the driver may contact the steering wheel directly or load the steering wheel and column through the inflated air bag. When the driver applies load to the air bag or steering wheel the column will compress downward absorbing some of the impact, helping to reduce bodily injuries to the driver. The steering wheel and column must be inspected for damage after a collision. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6575 Steering Wheel: Service and Repair Steering Wheel Replacement - Tools Required J 1859-A Steering Wheel Puller Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the steering wheel inflator module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotation the horn plunger 90 degrees. 4. Remove the steering wheel retaining nut. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6576 Notice: When removing the steering wheel, use only the specified steering wheel puller. Do not hammer on the end of the steering column shaft. Hammering could loosen the plastic injections, which maintain the steering column rigidity. 5. Install the J 1859-A to the steering wheel. 6. Remove the steering wheel using the J 1859-A. 7. Remove the J 1859-A from the steering wheel. Installation Procedure 1. Install the steering wheel to the steering shaft. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the steering wheel retaining nut. - Tighten the steering wheel retaining nut to 41 Nm (30 ft. lbs.). 3. Install the horn plunger to the steering column. 4. Install the steering wheel inflator module. 5. Enable the SIR system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications Tie Rod: Specifications Adjuster Tube Clamp Bolts 18 ft. lbs. Tie Rod to Relay Rod Nut 35 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6580 Tie Rod: Service and Repair Tie Rod Replacement - Tools Required J 6627-A Tie Rod Puller - J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm). Removal Procedure Important: Use the proper tool in order to separate all of the tie rods and the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the cotter pin and the castellated nut from the outer tie rod. Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. 3. Use the J24319-B in order to remove the outer tie rod from the steering knuckle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6581 4. Remove the prevailing torque nut from the inner tie rod. Discard the prevailing torque nut. 5. Use the J 6627-A in order to remove the inner tie rod from the relay rod. 6. Loosen the adjuster tube clamp bolts (3). 7. Unscrew the tie rod ends (1, 5). 8. Remove the tie rod ends (1, 5) from the adjuster tube (4). 9. Inspect the following components for damage: - The threads on the tie rod (1, 5) - The ball stud threads - The adjuster tube (4) for bending or damaged threads - The tie rod end seals for excessive wear 10. Clean the threads on the ball stud and in the ball stud nut. 11. Clean the tapered surfaces. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6582 Lubricate the tie rod threads with chassis lubricant if the tie rod ends were removed from the adjuster tube. 1. Loosen the clamps (2) on the adjuster tube (4). 2. Install the tie rod ends to the adjuster tube (4). The number of threads on the inner tie rod (5) and the outer tie rod (1) ends must be equal within 3 threads. Notice: Refer to Fastener Notice in Service Precautions. 3. Use the J29193 in order to install the inner tie rod to the relay rod. Ensure that the seal is on the stud. Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 4. Remove the J29193. 5. Install the new prevailing torque nut to the inner tie rod. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 6. Install the outer tie rod to the steering knuckle. Ensure that the seal is on the stud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6583 Important: Tighten the castellated nut up to an additional 1/6 amount in order to insert the cotter pin through the outer tie rod. Do not back the nut off in order to align the cotter pin hole. 7. Install the castellated nut. - Tighten the castellated nut to 49 Nm (36 ft. lbs.). 8. Install the new cotter pin. Bend the cotter pin ends flat against the nut flats. 9. Lower the vehicle. 10. Adjust the toe-in. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection Ball Joint: Testing and Inspection Ball Joint Inspection ^ Tools Required J 8001 Dial Indicator Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. ^ The upper control arm bumper must not contact the frame. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm with a floor stand or jack, as far outboard as possible, under the stabilizer bar bracket. Important: If a seal is cut or torn, replace the ball joint. 3. Clean and inspect the ball joints seals for cuts or tears. If the ball joint seals are damaged, replace the bail joint. 4. Check the wheel bearing for looseness. If looseness in the wheel bearing is present, refer to Wheel Bearings Diagnosis. 5. Check the ball joints for horizontal looseness. 5.1. Position the J8001 dial indicator against the lowest outboard point on the wheel rim. 5.2. Rock the wheel in and out while reading the dial indicator. This shows horizontal looseness in both joints. 5.3. The dial indicator reading should be no more than 2.00 mm (0.080 inch). If the reading is too high, check the lower ball joints for vertical looseness. Important: Do not support the lower control arm with a jack stand for a RWD vehicle, this will unload or cause compression on the wear indicator and will cause the wear indicator to give a false reading. 6. For RWD vehicles, check the lower ball joints for wear and for vertical looseness using the following procedure: 6.1. Remove the safety stand from under the lower control arm. 6.2. Inspect by sight the lower ball joint for wear. The position of the housing into which the grease fitting is threaded indicates wear. This round housing projects 1.27 mm (0.050 inch) beyond the surface of the ball joint cover on a new lower ball joint. Under normal wear, the surface of the ball joint housing retreats inward very slowly. 6.3. First observe, then scrape a scale, a screwdriver, or a fingernail across the cover. If the round housing is flush with or inside of the cover Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6588 surface, replace the lower ball joint. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 7. For 4WD vehicles, place a J 8001 dial indicator (1) against the spindle in order to show vertical movement. 8. Pry between the lower control arm (2) and the outer bearing race (1) while reading the dial indicator. This shows vertical looseness in the lower ball joints. The lower ball joint may show some looseness. 9. If the dial indicator reading is more than 3.18 mm (0.125 inch), replace the lower ball joint. 10. If the lower ball joint is within specifications, and there is too much horizontal looseness, check the upper ball joint for wear. 10.1. Disconnect the upper ball joint from the steering knuckle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6589 10.2. If you find any looseness or can twist the stud with your fingers, replace the upper ball joint. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6590 Ball Joint: Service and Repair Upper Ball Joint Replacement - Tools Required J 36607 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Caution: Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury. 2. Support the lower control arm with a safety stand. 3. Remove the tire and wheel. 4. Remove the brake hose bracket from the upper control arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6591 5. Remove the speed sensor bracket from the upper control arm. 6. Center punch rivets retaining the upper ball joint to the upper control arm. Use a 3.175 mm (1/8 inch) drill bit to cut a 6.35 mm (1/4 inch) deep hole in the center of each rivet. 7. Drill the rivet heads away using a 12.7 mm (1/2 inch) drill bit. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6592 8. Using a pin punch, remove the rivets. 9. Remove the cotter pin from the upper ball joint. 10. Remove the upper ball joint retaining nut. 11. Install the J 36607 to the upper ball joint and steering knuckle. 12. Disconnect the upper ball joint from the steering knuckle using J 36607. 13. Pull the upper control arm away from the steering knuckle. 14. Remove the upper ball joint. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6593 1. Install the upper ball joint to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper ball joint to the upper control arm mounting bolts and nuts. - Tighten the upper ball joint to the upper control arm mounting nuts to 30 Nm (22 ft. lbs.). 3. Install the speed sensor bracket to the upper control arm mounting bolt and nut. - Tighten the wheel sensor bracket to upper control arm mounting nut to 16 Nm (12 ft. lbs.). 4. Install the brake hose bracket to the upper control arm mounting bolt and nut. - Tighten the brake hose bracket to upper control arm mounting nut to 16 Nm (12 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6594 5. Connect the upper ball joint to the steering knuckle. 6. Install the upper ball joint to steering knuckle retaining nut. - Tighten the upper ball joint to steering knuckle retaining nut to 98 Nm (72 ft. lbs.). 7. Install a new cotter pin. Tighten the nut up to an additional 1/6 amount in order to insert the cotter pin through the upper ball joint stud. Bend the pin against the nut flats. 8. Install the upper ball joint grease fitting. 9. Using a grease gun, grease the upper ball joint until grease appears at the upper ball joint grease seal. 10. Install the tire and wheel. 11. Remove the safety stand from the lower control arm. 12. Lower the vehicle. 13. Check the front wheel alignment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Upper Control Arm Bushing: Service and Repair Upper Upper Control Arm Bushings Replacement Removal Procedure 1. Remove the upper control arm from the vehicle. 2. Remove the upper control arm bushings from the upper control arm. Installation Procedure 1. Install the upper control arm bushings into the upper control arm. 2. Install the upper control arm to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Upper > Page 6600 Control Arm Bushing: Service and Repair Lower Lower Control Arm Bushings Replacement - Tools Required J 9519-E Lower Ball Joint Remover and Installer - J 36618 Lower Control Arm Bushing Service Set Removal Procedure 1. Remove the lower control arm. 2. Remove the front bushing. 2.1. Unbend the crimps using a punch. 2.2. Remove the bushing using the J 36618-2, the J 9519-23, the J 36618-4, and the J 36618-1. 3. Remove the rear bushing (no crimp). Remove the bushing using the J 36618-5, the J 36618-3, the J 36618-2, and the J 9519-23. Installation Procedure 1. Install the front bushing using the J 36618 and the J 9519-23. After installing the bushing, crimp the bushing into place. 2. Install the rear bushing using the J 36618 and the J 9519-23. 3. Install the lower control arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody Cross-Member: Service and Repair Frame and Underbody Crossmember Brace Replacement - Front Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the bolts that retain the forward edge of the crossmember brace to the frame. 3. Remove the bolts and the nuts that retain the rear edge of the crossmember brace to the frame. 4. Remove the crossmember brace from the frame. Installation Procedure 1. Install the crossmember brace to the frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts and the nuts in order to retain the rear edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts and the nuts to 35 N.m (26 lb ft). 3. Install the bolts that retain the forward edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts to 35 N.m (26 lb ft). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 6605 Cross-Member: Service and Repair Frame Stop Replacement Frame Stop Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the bolts that retain the frame stop to the frame. 3. Remove the frame stop. Installation Procedure 1. Install the frame stop. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the frame stop to the frame. Tighten the bolts that retain the frame stop to 35 N.m (26 lb ft). 3. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 6606 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Support the transmission with a transmission jack. 3. Remove the two nuts securing the transmission mount to the transmission support. 4. Remove the transmission support nuts and bolts. 5. Remove the transmission support from the vehicle. Installation Procedure 1. Install the transmission support to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the transmission support nuts and bolts. Tighten the nuts and bolts to 70 N.m (52 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 6607 3. Install the two nuts securing the transmission mount to the transmission support. Tighten the nuts to 45 N.m (33 lb ft). 4. Remove the transmission jack. 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Recalls for Front Steering Knuckle: > NHTSA03V328000 > Aug > 03 > Recall 03V328000: Steering Knuckle Replacement Front Steering Knuckle: Recalls Recall 03V328000: Steering Knuckle Replacement DEFECT: Some of these minivans have an interference condition between the lower ball joint rubber boot and the steering knuckle (both left and right sides), which could result in cutting of the boot that is intended to seal the ball joint. If the lower ball joint boot were cut, contamination from the road (salt, dirt, water, etc.) could enter the ball socket area of the ball joint causing the joint to wear out too quickly. The steering knuckle could separate from the lower control arm, dropping down the affected corner of the vehicle. The coil spring would push the control arm down into contact with the ground, creating a drag that would slow the vehicle. The driver could have difficulty in maintaining the directional control of the vehicle. In addition, the affected wheel assembly could separate from the vehicle if forces resulting from the wheel's dragging action were sufficient to fracture the tie rod end and upper ball joint connections. Separation of the wheel assembly would also sever that wheel's hydraulic brake hose, resulting in lost braking performance from the front brake system. Vehicle stopping distance would increase, which could result in a crash. REMEDY: Dealers will replace the steering knuckles. The manufacturer has reported that owner notification is expected to begin during the first quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438, or GMC at 1-866-996-9463. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > NHTSA03V328000 > Aug > 03 > Recall 03V328000: Steering Knuckle Replacement Front Steering Knuckle: All Technical Service Bulletins Recall 03V328000: Steering Knuckle Replacement DEFECT: Some of these minivans have an interference condition between the lower ball joint rubber boot and the steering knuckle (both left and right sides), which could result in cutting of the boot that is intended to seal the ball joint. If the lower ball joint boot were cut, contamination from the road (salt, dirt, water, etc.) could enter the ball socket area of the ball joint causing the joint to wear out too quickly. The steering knuckle could separate from the lower control arm, dropping down the affected corner of the vehicle. The coil spring would push the control arm down into contact with the ground, creating a drag that would slow the vehicle. The driver could have difficulty in maintaining the directional control of the vehicle. In addition, the affected wheel assembly could separate from the vehicle if forces resulting from the wheel's dragging action were sufficient to fracture the tie rod end and upper ball joint connections. Separation of the wheel assembly would also sever that wheel's hydraulic brake hose, resulting in lost braking performance from the front brake system. Vehicle stopping distance would increase, which could result in a crash. REMEDY: Dealers will replace the steering knuckles. The manufacturer has reported that owner notification is expected to begin during the first quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438, or GMC at 1-866-996-9463. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6621 Front Steering Knuckle: Specifications Steering Knuckle to Tie Rod End Nut 36 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6622 Front Steering Knuckle: Service and Repair Steering Knuckle Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 36607 Ball Joint Separator - J 36605 Steering Knuckle Seal Installer Removal Procedure Caution: Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Unload the torsion bar. 4. Remove the wheel hub and bearing. 5. Remove the outer tie rod cotter pin and retaining nut. 6. Remove the outer tie rod from the steering knuckle using J 24319-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6623 7. Remove the upper ball joint cotter pin and retaining nut. 8. Install the J 36607 to the upper ball joint and the steering knuckle. 9. Disconnect the upper ball joint from the steering knuckle using the J 36607. 10. Remove the lower ball joint cotter pin and retaining nut. 11. Using a pry bar, placed on top of the upper control arm and on the bottom of the frame, pry downward. 12. With the aid of a helper, carefully hammer on the steering knuckle in the area of the lower ball joint stud in order to release the stud from the steering knuckle. 13. Place a pry bar on the top of the upper control arm and on the bottom of the frame, and pry downward. 14. With the aid of an assistant, carefully hammer on the steering knuckle in the area of the lower ball joint stud in order to release the stud from the steering knuckle. 15. Remove the steering knuckle. 16. Remove the seal from the steering knuckle. Installation Procedure 1. Install the seal into the steering knuckle using the J 36605. 2. Install the steering knuckle to the upper and lower ball joints. 3. Install the lower ball joint to steering knuckle retaining nut. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper ball joint to steering knuckle retaining nut. - Tighten the lower ball joint retaining nut to 128 Nm (95 ft. lbs.). - Tighten the upper ball joint retaining nut to 98 Nm (72 ft. lbs.). 5. Install the new cotter pins. Tighten the nuts up to an additional 1/6 amount in order to insert the cotter pin through the upper and lower ball joint studs. Bend the cotter pin ends flat against the nut. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6624 6. Install the outer tie rod ball stud to the steering knuckle. 7. Install the outer tie rod ball stud retaining nut. - Tighten the outer tie rod ball retaining nut to 49 Nm (36 ft. lbs.). 8. Install a new cotter pin to the outer tie rod stud nut. Bend the pin ends against the nut flats. 9. Install the hub and bearing assembly. 10. Load the torsion bar. 11. Install the tire and wheel. 12. Lower the vehicle. 13. Check the front wheel alignment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the idler arm to frame mounting bolts. 3. Disconnect the idler arms from the frame. Move the steering linkage to gain access to the stabilizer shaft bracket retaining bolts. 4. Remove the stabilizer shaft bracket mounting bolt and the nut (left hand). 5. Remove the stabilizer shaft bracket mounting bolts (right hand). 6. Remove the stabilizer shaft brackets. 7. Using a pry bar, lower the stabilizer shaft. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Page 6629 8. Remove the stabilizer shaft insulators from the stabilizer shaft. Installation Procedure 1. Using a pry bar, lower the stabilizer shaft. 2. Install the stabilizer shaft insulators to the stabilizer shaft. Make sure the slit in the stabilizer shaft insulator faces forward. 3. Install the stabilizer shaft brackets to the stabilizer shaft insulators. 4. Install the stabilizer shaft bracket mounting bolts (right hand). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the stabilizer shaft bracket mounting bolt and nut (left hand). - Tighten the stabilizer shaft bracket mounting bolts and the nut to 55 Nm (41 ft. lbs.). 6. Install the idler arms to the frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Page 6630 7. Install the idler arm mounting bolts. - Tighten the idler arm mounting bolts to 105 Nm (77 ft. lbs.). 8. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front Stabilizer Link: Specifications Stabilizer Shaft Link Nut or Bolt 13 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front > Page 6635 Stabilizer Link: Specifications Stabilizer Link Lower Nut 14 ft. lbs. Stabilizer Link Upper Nut 33 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 6636 Stabilizer Link: Service and Repair Stabilizer Shaft Link Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft link nut. 4. Remove the stabilizer shaft link bolt. 4.1. Pull the stabilizer shaft link bolt up through the retainers, the insulators, and the link spacer. 4.2. These components will come free, along with the end of the stabilizer shaft. Installation Procedure 1. Install the stabilizer shaft link insulator to the stabilizer shaft link bolt and insert the stabilizer shaft link bolt down through the stabilizer shaft. 2. Install stabilizer shaft link to the stabilizer shaft link bolt and insert the stabilizer shaft link bolt down through the lower control arm. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer link insulator and stabilizer shaft link retaining nut. ^ Tighten the stabilizer shaft link retaining nut to 17 Nm (13 ft. lbs.). 4. Install the tire and wheel. 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Specifications Shackle: Specifications Shackle to Frame Bolt 103 ft. lbs. Shackle to Spring 74 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Specifications > Page 6641 Shackle: Service and Repair Spring Shackle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the rear axle. 3. Remove the leaf spring to spring shackle mounting bolt and nut. 4. Remove the shock absorber lower mounting bolt and nut. Notice: Do not let the axle hang by the brake hose. Damage to the hose may occur. Always support the axle and the body separately. 5. Lower the rear axle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Specifications > Page 6642 6. Remove the spring shackle mounting nut. 7. Remove the spring shackle mounting bolt and the spring shackle. Installation Procedure 1. Install the spring shackle to the frame. 2. Install the spring shackle mounting bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the spring shackle mounting nut. - Tighten the spring shackle mounting nut to 140 Nm (103 ft. lbs.). 4. Raise the rear axle. 5. Install the lower shock absorber mounting bolt and nut. - Tighten the lower shock absorber mounting nut to 107 Nm (79 ft. lbs.). 6. Install the leaf spring to spring shackle mounting bolt and nut. - Tighten the leaf spring to spring shackle mounting nut to 100 Nm (74 ft. lbs.). 7. Remove the rear axle support. 8. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 6647 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front Suspension Strut / Shock Absorber: Specifications Shock Absorber Attaching Nuts 46 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 6650 Suspension Strut / Shock Absorber: Specifications Shock Absorber to Axle Nut 79 ft. lbs. Shock Absorber to Frame Nut 79 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm. 3. Remove the tire and wheel. 4. Remove the wheelhouse splash shield. 5. Remove the shock absorber lower mounting nut, the washer, and the bolt. 6. Remove the shock absorber upper mounting nut, the washer, and the bolt. 7. Remove the shock absorber. Installation Procedure 1. Install the shock absorber to the vehicle. Important: Position the bolts in the same direction that they removed or suspension clearance may be affected. 2. Install the shock absorber mounting bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the new shock absorber mounting nuts and the washers. - Tighten the shock absorber mounting nuts to 62 Nm (46 ft. lbs.). 4. Install the wheelhouse splash shield. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 6653 5. Install the tire and wheel. 6. Lower the vehicle. 7. Dispose of the shock absorber. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force, which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the center punch. 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a center punch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the center punch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a center punch. 5. Drill a second hole in the shock absorber at the center punch (2)- using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 6654 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the shock absorber upper mounting nut. 3. Remove the shock absorber lower mounting nut and the bolt (left hand). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 6655 4. Remove the shock absorber lower mounting bolt, the nut, and park brake cable bracket (right hand). 5. Remove the shock absorber from the vehicle. Installation Procedure 1. Install the shock absorber to the vehicle. 2. Install the shock absorber lower mounting bolt, the nut, and the parking brake bracket (right hand). 3. Install the shock absorber lower mounting bolt and the nut (left hand). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the shock absorber upper mounting nut. - Tighten the shock absorber upper and lower mounting nuts to 107 Nm (79 ft. lbs.). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 6656 5. Lower the vehicle. 6. Dispose of the shock absorber. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force, which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the center punch. 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a center punch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the center punch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil 4. Make an indentation in the middle (2) of the tube (3) with a center punch. 5. Drill a second hole in the shock absorber at the center punch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair Torsion Bar: Service and Repair Torsion Bar Replacement ^ Tools Required J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Notice: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Install the J 36202 to the torsion bar adjuster arm. 3. Using the J 36202, increase the tension on the adjustment arm. 4. Remove the adjustment bolt and the retaining nut. Record the number of turns required in order to remove the adjuster bolt. 5. Remove the J 36202 from the adjuster arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 6660 6. Slide the torsion bar forward and remove the adjustment arm. 7. Slide the torsion bar back partially through the crossmember. Important: Note the L for left and the R for right on the front end of the torsion bar because there are different bars for the left and right sides. 8. Drop the front end of the torsion bar down and slide the bar forward. Installation Procedure Important: Note the L for left or R for right on the front end of the torsion bar because there are different bars for the left and right sides. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 6661 1. Install the torsion bar. 2. Lubricate the adjuster arm and the bolt with axle grease 3. Install the torsion bar adjuster arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 6662 4. Install the adjustment bolt and retaining nut. Using the J 36202, increase the tension on the torsion bar. 5. Install the J 36202 to the adjuster arm. 6. Set the adjustment bolt to the recorded setting. 7. Using the J 36202, release the tension on the torsion bar until the load is taken up by the adjustment bolt. 8. Remove the J 36202. 9. Lower the vehicle. 10. Check the Z height. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6666 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 5 Wheel Bearings Diagnosis Step 6 - 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6667 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6668 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 6674 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 6675 Axle Nut: Specifications Axle Shaft Nut 147 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 6680 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 6681 Vehicle Lifting Points The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 6682 The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Spare Tire Carrier Mounting Bolts 11 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 6706 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Removal Procedure 1. Remove the spare tire from the tire carrier. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the pin and retainer from the shaft. 4. Remove the shaft from the hoist. 5. Remove the hoist mounting bolts. 6. Remove the hoist from the rear crossmember. Installation Procedure 1. Install the hoist to the rear crossmember. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hoist mounting bolts and nuts. ^ Tighten the hoist mounting bolts and nuts to 15 Nm (11 ft. lbs.). 3. Install the shaft to the hoist. 4. Install the pin and retainer to the shaft. 5. Lower the vehicle. 6. Install the spare tire to the carrier. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6715 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6716 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6717 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 6722 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6727 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6728 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6729 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6735 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6736 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6737 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 6742 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 6747 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 6748 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6753 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6754 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6755 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 6760 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6765 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6766 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6767 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6777 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6778 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6779 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 6784 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 6789 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 6790 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6795 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 200 - 229 mm (09 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6796 ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 6799 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrape ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6803 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 5 Wheel Bearings Diagnosis Step 6 - 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6804 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6805 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 6811 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 6812 Axle Nut: Specifications Axle Shaft Nut 147 ft. lbs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 6821 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 6827 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 04-03-10-004 > May > 04 > Wheels Wheel Fastener Torque Specification Update Wheel Fastener: All Technical Service Bulletins Wheels - Wheel Fastener Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 04-03-10-004 Date: May, 2004 SERVICE MANUAL UPDATE Subject: Revised Tire and Wheel Removal and Installation Fastener Tightening Specification Models: 2003 Chevrolet Astro Van 2003 GMC Safari Van This bulletin is being issued to revise the fastener tightening specification in the Tire and Wheel Removal and Installation procedure in the Tires and Wheels sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct tightening specification for the wheel nuts (Step 2 of Installation) is 190 N.m (140 lb ft). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 02-03-10-008 > Dec > 02 > Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 04-03-10-004 > May > 04 > Wheels Wheel Fastener Torque Specification Update Wheel Fastener: All Technical Service Bulletins Wheels - Wheel Fastener Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 04-03-10-004 Date: May, 2004 SERVICE MANUAL UPDATE Subject: Revised Tire and Wheel Removal and Installation Fastener Tightening Specification Models: 2003 Chevrolet Astro Van 2003 GMC Safari Van This bulletin is being issued to revise the fastener tightening specification in the Tire and Wheel Removal and Installation procedure in the Tires and Wheels sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct tightening specification for the wheel nuts (Step 2 of Installation) is 190 N.m (140 lb ft). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 02-03-10-008 > Dec > 02 > Wheels/Tires Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 6845 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 6846 Wheel Nut Torque Sequence Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the rotor. Important: Do not hammer on a wheel stud. 4. Remove the wheel stud using J 43631. Installation Procedure 1. Install the wheel stud to the wheel hub and bearing assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install 4 washers and the nut to the wheel stud. ^ Tighten the wheel stud nut to 130 Nm (95 ft. lbs.), drawing in the wheel stud. 3. Remove the nut and the washers from the wheel stud. 4. Install the rotor. 5. Install the tire and the wheel. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 6849 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement (Rear Drum Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the brake drum. 4. Remove the wheel stud from the axle flange using J 43631. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 6850 1. Start the new stud into the axle flange hole by pressing firmly with your hand. 2. Install a washer and thread the lug nut on the wheel stud with the flat side of the lug nut to the vehicle. 3. Tighten the lug nut in order to draw the wheel stud into the rear of the flange. 4. Remove the lug nut and washers from the wheel stud. 5. Install the brake drum. 6. Install the tire and the wheel. 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 6851 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6856 Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Disconnect the low pressure switch electrical connector. 3. Remove the low pressure switch. 4. Loosen the compressor suction hose nut (1) from the accumulator. 5. Remove the compressor suction hose from the accumulator. 6. Loosen the evaporator tube nut from the accumulator. 7. Remove the evaporator tube from the accumulator. 8. Remove and discard the O-ring seals. 9. Remove the accumulator mounting bracket bolt. 10. Remove the accumulator and mounting bracket. 11. Remove the accumulator from the mounting bracket. 12. Cap or tape off all open fittings. INSTALLATION PROCEDURE 1. Remove the caps or remove tape from the A/C fittings. 2. If replacing the accumulator, add the PAG oil to the accumulator. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6857 3. Install the accumulator to the mounting bracket. 4. Install the accumulator and mounting bracket to the module. 5. Install the accumulator mounting bracket bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 6. Install new O-ring seals. 7. Install the compressor suction hose (1) to the accumulator. 8. Tighten the compressor suction hose nut. Tighten Tighten the nut to 48 N.m (35 lb ft). 9. Install the evaporator tube to the accumulator. 10. Tighten the evaporator tube nut at the accumulator. Tighten Tighten the nut to 28 N.m (20 lb ft). 11. Install the low pressure switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6858 Tighten Tighten the switch to 6 N.m (53 lb in). 12. Connect the low pressure switch electrical connector. 13. Evacuate and charge the system. 14. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations IP Wiring,Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6863 IP Wiring, Right Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6864 Air Temperature Actuator Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6865 Air Door Actuator / Motor: Description and Operation AIR TEMPERATURE ACTUATOR The air temperature actuator is a 3 wire bi-directional electric motor. Ignition 3 voltage, ground and control circuits enable the actuator to operate. The control circuit uses a 0-12 volt linear-ramped signal to command the actuator movement. The 0 and 12 volt control values represent the opposite limits of the actuator range of motion. The values in between 0 and 12 voltscorrespond to the positions between the limits. When the HVAC control assembly sets a commanded, or targeted, value, the control signal is set to a value between 0-12 volts. The actuator shaft rotates until the commanded position is reached. The module will maintain the control value until a new commanded value is needed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Air Door Actuator / Motor: Service and Repair Air Temperature Actuator AIR TEMPERATURE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP extension. 2. Remove the engine cover. 3. Remove the screws that retain the actuator (1) to the heater assembly. 4. Disconnect the electrical connector (2). 5. Remove the air temperature actuator from the heater assembly. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 6868 1. Install the air temperature actuator to the heater assembly. 2. Connect the electrical connector. 3. Install the screws that retain the air temperature actuator (1) to the heater assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the engine cover. 5. Install the IP extension. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 6869 Air Door Actuator / Motor: Service and Repair Defroster Actuator DEFROSTER ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the right knee bolster. 2. Remove the right cowl trim panel. 3. Disconnect the vacuum hose from the defrost actuator. 4. Depress the retaining clip and remove the defrost actuator from the air distribution housing. INSTALLATION PROCEDURE 1. Install the defrost actuator to the air distribution housing. 2. Connect the vacuum hose to the defrost actuator. 3. Install the right cowl trim panel. 4. Install the right knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 6870 Air Door Actuator / Motor: Service and Repair Mode Actuator MODE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Remove the vacuum hose from the mode actuator. 3. Slide the actuator off the mounting bracket in order to remove the actuator. 4. Rotate the actuator (2) so that the actuator linkage slips off the post on the mode door linkage. 5. Remove the actuator linkage from the mode door linkage. INSTALLATION PROCEDURE 1. Rotate the actuator so that the actuator linkage slips over the post on the mode door linkage. 2. Install the actuator linkage to the mode door linkage. 3. Slide the actuator (2) onto the mounting bracket in order to install the actuator.Firmly press the actuator into place in order to fully seat the fastener. 4. Install the vacuum hose to the mode actuator. 5. Install the IP assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 6871 Air Door Actuator / Motor: Service and Repair Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger side knee bolster. 2. Remove the right cowl trim panel. 3. Remove the vacuum hose (3) from the recirculation actuator (2). 4. Remove the nuts that retain the recirculation actuator. 5. Remove the recirculation actuator from the recirculation door. INSTALLATION PROCEDURE 1. Install the recirculation actuator to the recirculation door. 2. Install the nuts that retain the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 N.m (18 lb in). 3. Install the vacuum hose (3) to the recirculation actuator (2). 4. Install the right cowl trim panel. 5. Install the passenger side knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement AIR DISTRIBUTOR DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Remove the left floor air outlet. 3. Remove the retaining screw at the IP assembly on the left side of the duct. 4. Remove the retaining clips from the air distributor assembly. 5. Remove the duct from the IP vent extensions. 6. Remove the air distributor duct from the IP. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6876 1. Install the air distributor duct to the IP. 2. Install the air distributor duct to the IP vent extensions. 3. Install the retaining clips to the air distributor assembly. 4. Install the retaining screws to the IP carrier on the left side of the duct. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to the IP carrier on the left side of the duct to 2 N.m (18 lb in). 5. Install the left floor air outlet. 6. Install the IP carrier. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6877 Air Duct: Service and Repair Air Outlet Duct Replacement - Auxiliary AIR OUTLET DUCT REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the left fourth pillar garnish molding. 2. Remove the set screw in the side of the 2 piece duct. 3. Slide the bottom half of the duct up into the top half. 4. Swing the bottom edge of the duct toward the interior of the vehicle. 5. Remove the top edge of the duct clear of the headliner duct. 6 Remove the air outlet duct from the vehicle. INSTALLATION PROCEDURE 1. Install the air outlet duct to the vehicle. 2. Install the top edge of the duct into the headliner duct. 3. Swing the bottom edge of the duct into the fourth pillar. 4. Swing the bottom edge of the duct into place over the auxiliary evaporator module. 5. Slide the bottom half of the duct down onto the auxiliary evaporator module. 6. Tighten the set screw on the side of the duct. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the set screw on the side of the duct to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6878 7. Install the left fourth pillar garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6879 Air Duct: Service and Repair Air Outlet Duct Replacement - Left Defogger AIR OUTLET DUCT REPLACEMENT - LEFT DEFOGGER REMOVAL PROCEDURE 1. Roll the instrument panel down. IMPORTANT: Do not remove the instrument panel. 2. Remove the duct from the left side floor air outlet. 3. Remove the duct from the left body side window defogger outlet. 4. Remove the duct from the vehicle. INSTALLATION PROCEDURE 1. Install the duct to the vehicle. 2. Install the duct to the left body side window defogger outlet. 3. Install the duct to the left side floor air outlet. 4. Roll the instrument panel up. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6880 Air Duct: Service and Repair Air Outlet Duct Replacement - Left Floor AIR OUTLET DUCT REPLACEMENT - LEFT FLOOR REMOVAL PROCEDURE 1. Remove the instrument panel carrier. 2. Remove the windshield defroster duct. 3. Remove the screws that retain the air outlet duct to the instrument panel carrier. 4. Remove the side window defroster ducts. 5. Remove the air outlet duct from instrument panel. INSTALLATION PROCEDURE 1. Install the air outlet duct to the instrument panel. 2. Install the side window defroster ducts. 3. Install the screws that retain the floor air outlet duct to the instrument panel carrier. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the windshield defroster duct. 5. Install the instrument panel carrier. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6881 Air Duct: Service and Repair Air Distributor Duct Replacement AIR DISTRIBUTOR DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Remove the left floor air outlet. 3. Remove the retaining screw at the IP assembly on the left side of the duct. 4. Remove the retaining clips from the air distributor assembly. 5. Remove the duct from the IP vent extensions. 6. Remove the air distributor duct from the IP. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6882 1. Install the air distributor duct to the IP. 2. Install the air distributor duct to the IP vent extensions. 3. Install the retaining clips to the air distributor assembly. 4. Install the retaining screws to the IP carrier on the left side of the duct. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to the IP carrier on the left side of the duct to 2 N.m (18 lb in). 5. Install the left floor air outlet. 6. Install the IP carrier. Air Outlet Duct Replacement - Auxiliary AIR OUTLET DUCT REPLACEMENT - AUXILIARY REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6883 1. Remove the left fourth pillar garnish molding. 2. Remove the set screw in the side of the 2 piece duct. 3. Slide the bottom half of the duct up into the top half. 4. Swing the bottom edge of the duct toward the interior of the vehicle. 5. Remove the top edge of the duct clear of the headliner duct. 6 Remove the air outlet duct from the vehicle. INSTALLATION PROCEDURE 1. Install the air outlet duct to the vehicle. 2. Install the top edge of the duct into the headliner duct. 3. Swing the bottom edge of the duct into the fourth pillar. 4. Swing the bottom edge of the duct into place over the auxiliary evaporator module. 5. Slide the bottom half of the duct down onto the auxiliary evaporator module. 6. Tighten the set screw on the side of the duct. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the set screw on the side of the duct to 2 N.m (18 lb in). 7. Install the left fourth pillar garnish molding. Air Outlet Duct Replacement - Left Defogger AIR OUTLET DUCT REPLACEMENT - LEFT DEFOGGER REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6884 1. Roll the instrument panel down. IMPORTANT: Do not remove the instrument panel. 2. Remove the duct from the left side floor air outlet. 3. Remove the duct from the left body side window defogger outlet. 4. Remove the duct from the vehicle. INSTALLATION PROCEDURE 1. Install the duct to the vehicle. 2. Install the duct to the left body side window defogger outlet. 3. Install the duct to the left side floor air outlet. 4. Roll the instrument panel up. Air Outlet Duct Replacement - Left Floor AIR OUTLET DUCT REPLACEMENT - LEFT FLOOR REMOVAL PROCEDURE 1. Remove the instrument panel carrier. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6885 2. Remove the windshield defroster duct. 3. Remove the screws that retain the air outlet duct to the instrument panel carrier. 4. Remove the side window defroster ducts. 5. Remove the air outlet duct from instrument panel. INSTALLATION PROCEDURE 1. Install the air outlet duct to the instrument panel. 2. Install the side window defroster ducts. 3. Install the screws that retain the floor air outlet duct to the instrument panel carrier. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the windshield defroster duct. 5. Install the instrument panel carrier. Air Outlet Duct Replacement - Left Lap AIR OUTLET DUCT REPLACEMENT - LEFT FLOOR REMOVAL PROCEDURE 1. Remove the left knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6886 2. Remove the screws that retain the outlet duct. 3. Remove the duct from the air distribution duct. INSTALLATION PROCEDURE 1. Install the duct to the air distribution duct. 2. Install the outlet duct. 3. Install the screws that retain the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the left knee bolster. Air Outlet Duct Replacement - Right Defogger AIR OUTLET DUCT REPLACEMENT - RIGHT DEFOGGER REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6887 1. Roll the instrument panel down. IMPORTANT: Do not remove the instrument panel. 2. Remove the screws that retain the duct. 3. Remove the duct from the instrument panel. INSTALLATION PROCEDURE 1. Install the duct to the instrument panel. 2. Install the screws in order to retain the duct. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Roll the instrument panel up. Air Outlet Duct Replacement - Right Lap AIR OUTLET DUCT REPLACEMENT - RIGHT LAP REMOVAL PROCEDURE 1. Remove the right knee bolster. 2. Remove the air outlet duct from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 6888 1. Install the air outlet duct to the vehicle. 2. Install the right knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor Air Register: Service and Repair Air Outlet Replacement - Center Floor AIR OUTLET REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE 1. Remove the IP extension. 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. 4. Remove the front section of the carpet, if equipped. 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6893 1. Install the floor air outlet to the ducts to the rear seat, if equipped. 2. Install the retaining nuts to the floor outlet duct, if equipped. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 N.m (18 lb in). 3. Install the front section of the carpet, if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct from the air distributor. 6. Install the IP extension. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6894 Air Register: Service and Repair Air Outlet Replacement - Defroster AIR OUTLET REPLACEMENT - DEFROSTER REMOVAL PROCEDURE 1. Roll the instrument panel down. IMPORTANT: Do not remove the instrument panel. 2. Remove the windshield defroster duct grille from the instrument panel. 3. Remove the windshield defroster duct retainers from the instrument panel. 4. Remove the retaining screw on the instrument panel carrier. 5. Remove the windshield defroster duct by rotating the duct downward and away from the instrument panel. INSTALLATION PROCEDURE 1. Install the windshield defroster duct to the instrument panel. 2. Install the retaining screw to the instrument panel carrier. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 3. Install the windshield defroster duct retainers to the instrument panel. 4. Install the windshield defroster duct grille to the instrument panel. 5. Roll the instrument panel up. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6895 Air Register: Service and Repair Air Outlet Replacement - Instrument Panel AIR OUTLET REPLACEMENT - INSTRUMENT PANEL REMOVAL PROCEDURE 1. Remove the right side knee bolster. 2. Remove the screw that retains the air outlet vent to the I/P. 3. Lift upward on the I/P assist handle. 4. Remove the air outlet vent from the I/P. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6896 1. Lift upward on the I/P assist handle. 2. Install the air outlet vent to the I/P. 3. Install the screw that retains the air outlet vent to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Install the right side knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6897 Air Register: Service and Repair Air Outlet Replacement - Lap AIR OUTLET REPLACEMENT - LAP REMOVAL PROCEDURE 1. Remove the instrument panel extension. 2. Remove the driver side knee bolster. 3. Remove the nuts that retain the knee bolster lap deflector to the instrument panel carrier (IPC). 4. Remove the bolts that retain the knee bolster lap deflector to the IPC. 5. Remove the knee bolster lap deflector from the vehicle. INSTALLATION PROCEDURE 1. Install the knee bolster lap deflector to the vehicle. 2. Install the bolts that retain the knee bolster lap deflector to the IPC. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Install the bolts that retain the knee bolster lap deflector to the IPC. Tighten Tighten the bolts to 10 N.m (89 lb in). 4. Install the driver side knee bolster. 5. Install the instrument panel extension. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6898 Air Register: Service and Repair Air Outlet Replacement - Center Floor AIR OUTLET REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE 1. Remove the IP extension. 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. 4. Remove the front section of the carpet, if equipped. 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6899 1. Install the floor air outlet to the ducts to the rear seat, if equipped. 2. Install the retaining nuts to the floor outlet duct, if equipped. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 N.m (18 lb in). 3. Install the front section of the carpet, if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct from the air distributor. 6. Install the IP extension. Air Outlet Replacement - Defroster AIR OUTLET REPLACEMENT - DEFROSTER REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6900 1. Roll the instrument panel down. IMPORTANT: Do not remove the instrument panel. 2. Remove the windshield defroster duct grille from the instrument panel. 3. Remove the windshield defroster duct retainers from the instrument panel. 4. Remove the retaining screw on the instrument panel carrier. 5. Remove the windshield defroster duct by rotating the duct downward and away from the instrument panel. INSTALLATION PROCEDURE 1. Install the windshield defroster duct to the instrument panel. 2. Install the retaining screw to the instrument panel carrier. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 3. Install the windshield defroster duct retainers to the instrument panel. 4. Install the windshield defroster duct grille to the instrument panel. 5. Roll the instrument panel up. Air Outlet Replacement - Instrument Panel AIR OUTLET REPLACEMENT - INSTRUMENT PANEL REMOVAL PROCEDURE 1. Remove the right side knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6901 2. Remove the screw that retains the air outlet vent to the I/P. 3. Lift upward on the I/P assist handle. 4. Remove the air outlet vent from the I/P. INSTALLATION PROCEDURE 1. Lift upward on the I/P assist handle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6902 2. Install the air outlet vent to the I/P. 3. Install the screw that retains the air outlet vent to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Install the right side knee bolster. Air Outlet Replacement - Lap AIR OUTLET REPLACEMENT - LAP REMOVAL PROCEDURE 1. Remove the instrument panel extension. 2. Remove the driver side knee bolster. 3. Remove the nuts that retain the knee bolster lap deflector to the instrument panel carrier (IPC). 4. Remove the bolts that retain the knee bolster lap deflector to the IPC. 5. Remove the knee bolster lap deflector from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6903 1. Install the knee bolster lap deflector to the vehicle. 2. Install the bolts that retain the knee bolster lap deflector to the IPC. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Install the bolts that retain the knee bolster lap deflector to the IPC. Tighten Tighten the bolts to 10 N.m (89 lb in). 4. Install the driver side knee bolster. 5. Install the instrument panel extension. Air Outlet Replacement - Left Floor AIR OUTLET REPLACEMENT - LEFT FLOOR REMOVAL PROCEDURE 1. Remove the instrument panel carrier. 2. Remove the windshield defroster duct. 3. Remove the screws that retain the air outlet duct to the instrument panel carrier. 4. Remove the side window defroster ducts. 5. Remove the air outlet duct from instrument panel. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6904 1. Install the air outlet duct to the instrument panel. 2. Install the side window defroster ducts. 3. Install the screws that retain the floor air outlet duct to the instrument panel carrier. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the windshield defroster duct. 5. Install the instrument panel carrier. Air Outlet Replacement - Rear Floor AIR OUTLET REPLACEMENT - REAR FLOOR REMOVAL PROCEDURE 1. Remove the IP extension. 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. 4. Remove the front section of the carpet if equipped. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6905 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE 1. Install the floor air outlet to the ducts to the rear seat, if equipped. 2. Install the retaining nuts to the floor outlet duct, if equipped. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 N.m (18 lb in). 3. Install the front section of the carpet if equipped. 4. Install the bucket seats. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6906 5. Install the floor air outlet duct to the air distributor. 6. Install the IP extension. Deflector Replacement - Auxiliary A/C Outlet - Headliner DEFLECTOR REPLACEMENT - AUXILIARY A/C OUTLET - HEADLINER REMOVAL PROCEDURE 1. Use a flat blade tool in order to remove the air deflector from the headliner. 2. Remove the air deflector from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6907 1. Align the air deflector into the opening in the headliner. 2. Push the air outlet into the headliner until the deflector snaps into place. Grille Replacement - Body Side Rear Trim Air Outlet GRILLE REPLACEMENT - BODY SIDE REAR TRIM AIR OUTLET REMOVAL PROCEDURE Pull out ward on the vent in order to remove the vent from the trim panel. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 6908 Press the vent inward in order to install the vent to the trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 6912 Ambient Temperature Sensor / Switch HVAC: Locations Front End Center Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 6913 Front End Center Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 6914 Ambient Air Temperature Sensor (DIC) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 6915 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the outside air temperature sensor from the center support bracket by sliding the sensor upward. 3. Disconnect the temperature sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the temperature sensor electrical connector. 2. Install the temperature sensor by sliding the sensor downward. 3. Install the radiator grille to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6924 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6925 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6926 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The blower motor relay that is used on this vehicle is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). 2. Install the screws to the blower motor resistor assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the windshield washers and the coolant reservoir. 4. Connect the electrical connectors. 5. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Rear Heater Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7011 A/C Wiring Rear Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor - A/C Auxiliary Blower Motor Resistor- A/C Auxiliary Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor - A/C Auxiliary > Page 7014 Blower Motor Resistor Assembly Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor - A/C Auxiliary > Page 7015 Blower Motor Resistor-Heater Auxiliary Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (With RPO Code YG6) Blower Motor Resistor: Service and Repair Blower Motor Resistor Assembly Replacement (With RPO Code YG6) BLOWER MOTOR RESISTOR ASSEMBLY REPLACEMENT (With RPO Code YG6) REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly. INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly. 2. Install the screws to the blower motor resistor assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connectors. 4. Install the windshield washers and the coolant reservoir. 5. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (With RPO Code YG6) > Page 7018 Blower Motor Resistor: Service and Repair Blower Motor Resistor Assembly Replacement (With RPO Code C60) BLOWER MOTOR RESISTOR ASSEMBLY REPLACEMENT (With RPO Code C60) REMOVAL PROCEDURE IMPORTANT: The blower motor relay is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). 2. Install the screws to the blower motor resistor assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connectors. 4. Install the windshield washers and the coolant reservoir. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (With RPO Code YG6) > Page 7019 5. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (With RPO Code YG6) > Page 7020 Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement - Auxiliary A/C BLOWER MOTOR RESISTOR REPLACEMENT - AUXILIARY AIR CONDITIONING(A/C) REMOVAL PROCEDURE 1. Remove the left body side trim panel. 2. Remove the electrical connector. 3. Remove the screws that retain the resistor (4) to the case. 4. Remove the auxiliary A/C blower motor resistor assembly from the case. INSTALLATION PROCEDURE 1. Install the auxiliary A/C blower motor resistor assembly into the case. 2. Install the screws that retain the resistor to the case. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the electrical connector. 4. Install the left body side rear trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (With RPO Code YG6) > Page 7021 Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement - Heater Auxiliary BLOWER MOTOR RESISTOR REPLACEMENT - HEATER AUXILIARY REMOVAL PROCEDURE 1. Remove the left body side trim panel. 2. Remove the electrical connector. 3. Remove the screws from the auxiliary heater blower motor resistor assembly. 4. Remove the auxiliary heater blower motor resistor assembly (1) from the heater case. INSTALLATION PROCEDURE 1. Install the auxiliary heater blower motor resistor assembly (1) into the heater case. 2. Install the auxiliary heater blower motor resistor assembly screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the electrical connector. 4. Install the left body side rear trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary Blower Motor Switch-A/C Auxiliary Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary > Page 7027 Blower Motor Switch: Diagrams Blower Motor Switch - Heater Auxiliary Blower Motor Switch-Heater Auxiliary Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary > Page 7028 Blower Motor Switch-Heater Auxiliary Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Auxiliary A/C BLOWER MOTOR SWITCH REPLACEMENT - AUXILIARY A/C REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary A/C blower motor switch (2) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 7031 1. Install the auxiliary A/C blower motor switch (2) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 7032 Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Heater Auxiliary BLOWER MOTOR SWITCH REPLACEMENT - HEATER AUXILIARY REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary heat blower motor switch (1) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 7033 1. Install the auxiliary heat blower motor switch (1) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Information not supplied by the manufacturer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7038 A/C Component Clutch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal Compressor Clutch: Service and Repair Compressor Clutch Plate and Hub Assembly Removal COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL TOOLS REQUIRED - J 34992 Compressor Holding Fixture - J 33013-B Hub and Drive Plate Remover/Installer 1. Clamp the J 34992 in a vise. 2. Use thumb screws in order to attach the compressor to the holding fixture. 3. Ensure that the center screw forces the tip to thrust against the end of the shaft. NOTE: Do not drive or pound on the clutch hub or shaft.Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 4. Thread the J 33013-B into the hub. 5. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1). 6. Remove the shaft key. Retain the shaft key for reassembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7041 Compressor Clutch: Service and Repair Compressor Clutch Plate/Hub Assembly Installation COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL TOOLS REQUIRED J 33013-B Hub and Drive Plate Remover/Installer 1. Install the shaft key (4) into the hub key groove.Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 2. Clean the following components: - The clutch plate - The clutch rotor (2) 3. Align the shaft key (4) with the shaft keyway (3). 4. Place the clutch plate and the hub assembly (1) onto the compressor shaft. 5. Remove the forcing tip on the J 33013-B. 6. Reverse the body direction on the center screw. 7. Install the J 33013-B with the bearing. 8. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 9. Hold the center screw with a wrench. 10. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 11. Tighten the body several turns. 12. Remove the installer. Ensure that the shaft key remains in place in the keyway. 13. Install the clutch plate and hub assembly to the final position.Ensure that the air gap (2) between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76 mm (0.20-0.30 in). 14. Remove the J 33013-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7042 15. Verify proper positioning of the shaft key.Ensure that the shaft key is even with or slightly above the clutch hub. 16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7043 Compressor Clutch: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 33013-B Hub and Drive Plate Installer - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Remove the compressor from the vehicle. 3. Use the Compressor Holding Fixture HD-6 tool in order to hold the compressor in a vise. 4. Use both thumb screws in order to attach the compressor to the holding fixture. 5. Install the compressor into a vise. 6. Remove the shaft protector from the clutch hub shaft. 7. Ensure that the center screw forces the tip to thrust against the end of the shaft. NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 8. Thread the J 33013-B into the hub. 9. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly. 10. Remove the shaft key. Retain the shaft key for reassembly. 11. Remove the old clutch plate and hub assembly from the compressor. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7044 1. Install the shaft key (4) into the hub key groove. 2. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 3. Clean the following components: - The clutch plate - The clutch rotor (2) 4. Align the shaft key (4) with the shaft keyway (3). 5. Place the clutch plate and the hub assembly (1) onto the compressor shaft. 6. Install the forcing tip on the J 33013-B. 7. Reverse the body direction on the center screw. 8. Install the J 33013-B with the bearing. 9. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 10. Hold the center screw with a wrench. 11. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 12. Tighten the body several turns. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7045 13. Install the clutch plate and hub assembly to the final position.Ensure that the air gap between frictional surfaces of the clutch plate and clutch rotor measures within 3.81-0.51 mm (0.15-0.20 in). 14. Check the clutch plate and hub assembly in three places for clearance. 15. Remove the installer. Ensure that the shaft key remains in place in the keyway. 16. Remove the J 33013-B. 17. Verify proper positioning of the shaft key.Ensure that the shaft key is even with or slightly above the clutch hub. 18. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. 19. Install the shaft protector to the clutch hub shaft. 20. Remove both thumb screws from the compressor holding fixture Compressor Holding Fixture HD-6 Compressor Holding Fixture HD-6. 21. Remove theCompressor Holding Fixture HD-6 Compressor Holding Fixture HD-6 tool from the vise. 22. Install the compressor to the vehicle. 23. Evacuate and recharge the refrigerant system. 24. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Removal CLUTCH ROTOR AND/OR BEARING REMOVAL TOOLS REQUIRED - J 6083 Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Pulley Puller - J 29886 Driver Handle - J 9398-A Bearing Remover 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the following components: - The pulley rotor (1) - The bearing assembly retaining ring (2) 3. Install the J 33023-A to the front head. 4. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7050 5. Turn the J 41552 clockwise in the slots in the rotor. 6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly. 7. Use the following procedure in order to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: 7.1. Remove the forcing screw from the J 41552. 7.2. Ensure that the puller tangs still engage in the rotor slots. 7.3. Invert the assembly onto a solid flat surface or blocks. 8. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7051 Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Installation CLUTCH ROTOR AND/OR BEARING INSTALL TOOLS REQUIRED - J 6083 Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Pulley Puller - J 29886 Driver Handle - J 21352-A Support Block - J 9481-A Bearing Installer - J 33019 Bearing Staking Tool - J 33017 Pulley and Bearing Assembly Installer - J 8433-1 Puller Bar - J 9398-A Bearing Remover - J 34992 Holding Fixture 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation. NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 2. Use the following tools in order to align the new bearing squarely with the hub bore: - The J 41552 - The J 9481-A - The J 29886 3. Drive the bearing fully into the hub.The installer will apply force to the outer race of the bearing, if used as shown. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7052 4. Place the J 33019 in the hub bore. 5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the staking pin location.Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin. 6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing. IMPORTANT: Use care in order to prevent personal injury when striking the staking pin with a hammer. 7. Stake 3 locations on the bearing race 120 degrees apart as shown. IMPORTANT: Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing. 8. With the compressor mounted on the J 34992, position the pulley rotor (1) and the bearing assembly on the front head. 9. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 10. Position the J 8433-1 on the J 33023-A. 11. Assemble the 2 through bolts and the washers through the puller bar slots. 12. Thread the through bolts into the J 34992.Ensure that the thread of the through bolts engage the full thickness of the J 34992. 13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head.If the J 33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps: 13.1. Loosen the J 8433-3. 13.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7053 14. Use the snap ring pliers in order to install the following components: 14.1. The pulley rotor (1) 14.2. The retaining ring (2) 14.3. Install the clutch plate and hub assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7054 Compressor Clutch Bearing: Service and Repair Clutch Rotor, Bearing (With RPO Code HT6/HD6/HU6) CLUTCH ROTOR AND/OR BEARING REPlACEMENT (WITH RPO CODE HT6/HD6/HU6) REMOVAL PROCEDURE TOOLS REQUIRED - J 6083 External Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Compressor Pulley Puller - J 29886 Driver Handle - J 21352-A Support Block - J 9481-A Bearing Installer - J 33019 Pulley Bearing Staking Tool - J 33017 Pulley and Bearing Installer - J 8433-1 Puller Bar - J 9398-A Rotor Bearing Remover - J 34992 Compressor Holding Fixture 1. Remove the A/C compressor. 2. Remove the clutch plate and hub assembly. 3. Use the J 6083 in order to remove the following components: - The pulley rotor (1) - The bearing assembly retaining ring (2) 4. Install the J 33023-A to the front head. 5. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7055 6. Turn the J 41552 clockwise in the slots in the rotor. 7. Perform the following steps in order to remove the pulley rotor and bearing assembly: 7.1. Hold the J 41552 in position. 7.2. Tighten the puller screw against the puller guide. 7.3. Remove the pulley rotor and bearing assembly. 8. Use the following procedure to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: 8.1. Remove the forcing screw from the J 41552. 8.2. Ensure that the puller tangs still engage in the rotor slots. 8.3. Invert the assembly onto a solid flat surface or blocks. 9. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. INSTALLATION PROCEDURE 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation. NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 2. Use the following tools in order to align the new bearing squarely with the hub bore: - The J 41552 - The J 9481-A - The J 29886 3. Drive the bearing fully into the hub.The installer will apply force to the outer race of the bearing, if used as shown. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7056 4. Place the J 33019 in the hub bore. 5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the staking pin location.Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin. 6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing. IMPORTANT: Use care in order to prevent personal injury when striking the staking pin with a hammer. 7. Stake 3 locations on the bearing race 120 degrees apart as shown. IMPORTANT: Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7057 8. With the compressor mounted on the J 34992, position the pulley rotor (1) and the bearing assembly on the front head. 9. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 10. Position the J 8433-1 on the J 33023-A. 11. Assemble the 2 through bolts and the washers through the puller bar slots. 12. Thread the through bolts into the J 34992.Ensure that the thread of the through bolts engage the full thickness of the J 34992. 13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head.If the J 33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps: 13.1. Loosen the J 8433-3. 13.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. 14. Use the snap ring pliers in order to install the following components: 14.1. The pulley rotor (1) 14.2. The retaining ring (2) 14.3. Install the clutch plate and hub assembly. 14.4. Install the A/C compressor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Removal COMPRESSOR CLUTCH COIL REMOVAL TOOLS REQUIRED - J 6083 Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Pulley Puller - J 8433-1 Puller Bar - J 33025 Clutch Coil Puller Legs - J 8433-3 Forcing Screw 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the following components: - The pulley rotor (1) - The bearing assembly retaining ring (2) 3. Install the J 33023-A to the front head. 4. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7062 5. Turn the J 41552 clockwise in the slots in the rotor. 6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly. 7. Mark the clutch coil terminal location (1) on the compressor front head. 8. Install the J 33023-A on the front head of the compressor. 9. Install the J 8433-1 and the J 33025. 10. Tighten the J 8433-3 against the puller pilot in order to remove the clutch coil (2). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7063 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Replacement COMPRESSOR CLUTCH COIL REPLACEMENT TOOLS REQUIRED - J 6083 Snap Ring Pliers - J 8433-1 Puller Bar - J 8433-3 Forcing Screw - J 33017 Pulley and Bearing Assembly Installer - J 33023-A Puller Pilot - J 33024 Clutch Coil Installer Adapter - J 33025 Clutch Coil Puller Legs - J 39400-A Halogen Leak Detector - J 34992 Holding Fixture - J 41552 Pulley Puller REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Remove the compressor from the vehicle. 3. Remove the clutch plate and hub assembly. 4. Use the J 6083 in order to remove the following components: - The pulley rotor - The bearing assembly retaining ring 5. Install the J 33023-A to the front head. 6. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7064 7. Turn the J 41552 clockwise in the slots in the rotor. 8. Perform the following steps in order to remove the pulley rotor and bearing assembly: 8.1. Hold the J 41552 in position. 8.2. Tighten the puller screw against the puller guide. 8.3. Remove the pulley rotor and bearing assembly. 9. Mark the clutch coil terminal location (1) on the compressor front head. 10. Install the J 33023-A on the front head of the compressor. 11. Install the J 8433-1 and the J 33025. 12. Tighten the J 8433-3 against the puller pilot in order to remove the clutch coil (2). 13. Remove the clutch coil from the compressor. INSTALLATION PROCEDURE 1. Install the clutch coil to the compressor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7065 2. Place the clutch coil assembly on the front head. Position the terminals (1) at the marked location. 3. Place the J 33024 over the internal opening of the clutch coil housing (1). 4. Align the J 33024 with the compressor front head. 5. Center the J 8433-1 in the counter-sunk center hole of the J 33024. 6. Install the two bolts and washers through the crossbar slots. 7. Thread the bolts into the J 34992 in order to achieve full fixture thickness. 8. Turn the center forcing screw of the J 8433-1 in order to force the clutch coil onto the front head. Ensure that the clutch coil and the J 33024 remain aligned during installation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7066 9. When the coil is fully seated on the front head, mark the front head at 3 places 120 degrees apart. 10. Use a 1/8 inch diameter drift punch (2) in order to stake the front head at 3 places 120 degrees apart (3), in order to ensure that the clutch coil (1) remains in position. IMPORTANT: Ensure that the stake size is only one-half the area of the punch tip. Ensure that the stake is only approximately 0.28-0.35 mm (0.010-0.015 in) deep. 11. With the compressor mounted to the J 34992, position the pulley rotor (1) and bearing assembly on the front head. 12. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 13. Position the J 8433-1 on the J 33023-A. 14. Assemble the two bolts and washers through the puller bar slots. 15. Thread the bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 16. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. 17. If the J 33017 slips off direct in-line contact with the inner race and bearing, perform the following steps: 17.1. Loosen the J 8433-3. 17.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7067 18. Use the J 6083 in order to install the following components: - The pulley rotor (1) - The retainer ring (2) 19. Install the clutch plate and hub assembly. 20. Install the compressor to the vehicle. 21. Evacuate and recharge the refrigerant system. 22. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7068 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Installation COMPRESSOR PRESSURE RELIEF VALVE REMOVAL TOOLS REQUIRED - J 33024 Clutch Coil Installer Adapter - J 8433-1 Puller Bar - J 34992 Holding Fixture - J 33017 Pulley and Bearing Assembly Installer - J 33023-A Puller Pilot - J 6083 Snap Ring Pliers 1. Place the clutch coil assembly (1) on the front head. Position the terminals at the marked location. 2. Place the J 33024 over the internal opening of the clutch coil housing. 3. Align the J 33024 with the compressor front head. 4. Center the J 8433-1 in the counter-sunk center hole of the J 33024. 5. Install the 2 through bolts and washers through the crossbar slots. 6. Thread the bolts into the J 34992 in order to achieve full fixture thickness. 7. Turn the center forcing screw of the J 8433-1 in order to force the clutch coil onto the front head. Ensure that the clutch coil and the J 33024 remain aligned during installation. 8. When the coil is fully seated on the front head, use a 1/8 inch diameter drift punch (2) in order to stake the front head at 3 places 120 degrees apart (3), in order to ensure that the clutch coil (1) remains in position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7069 9. Ensure that the stake size is only one-half the area of the punch tip. Ensure that the stake is only approximately 0.28-0.35 mm (0.010-0.015 in) deep. 10. With the compressor mounted to the J 34992, position the pulley rotor (1) and bearing assembly on the front head. 11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 12. Position the J 8433-1 on the J 33023-A. 13. Assemble the 2 through bolts and washers through the puller bar slots. 14. Thread the bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 15. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head.If the J 33017 slips off direct in-line contact with the inner race and bearing, perform the following steps: 15.1. Loosen the J 8433-3. 15.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7070 16. Use the J 6083 in order to install the following components: - The pulley rotor (1) - The retainer ring (2) 17. Install the clutch plate and hub assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal Compressor Clutch Hub: Service and Repair Compressor Clutch Plate and Hub Assembly Removal COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL TOOLS REQUIRED - J 34992 Compressor Holding Fixture - J 33013-B Hub and Drive Plate Remover/Installer 1. Clamp the J 34992 in a vise. 2. Use thumb screws in order to attach the compressor to the holding fixture. 3. Ensure that the center screw forces the tip to thrust against the end of the shaft. NOTE: Do not drive or pound on the clutch hub or shaft.Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 4. Thread the J 33013-B into the hub. 5. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1). 6. Remove the shaft key. Retain the shaft key for reassembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7075 Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Installation COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL TOOLS REQUIRED J 33013-B Hub and Drive Plate Remover/Installer 1. Install the shaft key (4) into the hub key groove.Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 2. Clean the following components: - The clutch plate - The clutch rotor (2) 3. Align the shaft key (4) with the shaft keyway (3). 4. Place the clutch plate and the hub assembly (1) onto the compressor shaft. 5. Remove the forcing tip on the J 33013-B. 6. Reverse the body direction on the center screw. 7. Install the J 33013-B with the bearing. 8. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 9. Hold the center screw with a wrench. 10. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 11. Tighten the body several turns. 12. Remove the installer. Ensure that the shaft key remains in place in the keyway. 13. Install the clutch plate and hub assembly to the final position.Ensure that the air gap (2) between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76 mm (0.20-0.30 in). 14. Remove the J 33013-B. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7076 15. Verify proper positioning of the shaft key.Ensure that the shaft key is even with or slightly above the clutch hub. 16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7077 Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 33013-B Hub and Drive Plate Installer - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Remove the compressor from the vehicle. 3. Use the Compressor Holding Fixture HD-6 tool in order to hold the compressor in a vise. 4. Use both thumb screws in order to attach the compressor to the holding fixture. 5. Install the compressor into a vise. 6. Remove the shaft protector from the clutch hub shaft. 7. Ensure that the center screw forces the tip to thrust against the end of the shaft. NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 8. Thread the J 33013-B into the hub. 9. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly. 10. Remove the shaft key. Retain the shaft key for reassembly. 11. Remove the old clutch plate and hub assembly from the compressor. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7078 1. Install the shaft key (4) into the hub key groove. 2. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 3. Clean the following components: - The clutch plate - The clutch rotor (2) 4. Align the shaft key (4) with the shaft keyway (3). 5. Place the clutch plate and the hub assembly (1) onto the compressor shaft. 6. Install the forcing tip on the J 33013-B. 7. Reverse the body direction on the center screw. 8. Install the J 33013-B with the bearing. 9. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 10. Hold the center screw with a wrench. 11. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 12. Tighten the body several turns. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7079 13. Install the clutch plate and hub assembly to the final position.Ensure that the air gap between frictional surfaces of the clutch plate and clutch rotor measures within 3.81-0.51 mm (0.15-0.20 in). 14. Check the clutch plate and hub assembly in three places for clearance. 15. Remove the installer. Ensure that the shaft key remains in place in the keyway. 16. Remove the J 33013-B. 17. Verify proper positioning of the shaft key.Ensure that the shaft key is even with or slightly above the clutch hub. 18. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. 19. Install the shaft protector to the clutch hub shaft. 20. Remove both thumb screws from the compressor holding fixture Compressor Holding Fixture HD-6 Compressor Holding Fixture HD-6. 21. Remove theCompressor Holding Fixture HD-6 Compressor Holding Fixture HD-6 tool from the vise. 22. Install the compressor to the vehicle. 23. Evacuate and recharge the refrigerant system. 24. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7083 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center. 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7087 Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Recover the refrigerant from the system. 3. Remove the grille. 4. Loosen the compressor hose assembly nut at the condenser. 5. Remove the compressor hose assembly from the condenser. 6. Loosen the evaporator tube nut at the condenser. 7. Remove the evaporator tube from the condenser. 8. Remove the center support bracket. 9. Remove the bolts that retain the condenser to the radiator. 10. Remove the condenser from the radiator. 11. Remove and discard the O-ring seals. INSTALLATION PROCEDURE 1. If replacing the condenser, add the PAG oil to the condenser. 2. Install the condenser to the radiator. 3. Install the bolts that retain the condenser to the radiator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7088 Tighten Tighten the bolts to 6 N.m (53 lb in). 4. Install the center support bracket. 5. Install new O-ring seals. 6. Install the evaporator tube to the condenser. 7. Tighten the evaporator tube nut. Tighten Tighten the nut to 28 N.m (21 lb ft). 8. Install new O-ring seals. 9. Install the compressor hose assembly to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 10. Install the grille. 11. Evacuate and recharge the system. 12. Leak test the fittings of the component using the J 39400-A. 13. Install the air cleaner assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Control Knob Replacement Availability Control Assembly: Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7093 Control Assembly: Locations Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7094 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7095 Control Assembly: Diagrams HVAC Control Assembly C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7096 HVAC Control Assembly C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7097 HVAC Control Assembly C3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7098 Control Assembly: Description and Operation HVAC CONTROL MODULE The HVAC control assembly is a non-class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive and ignition 3 voltage circuits provide power to the control assembly. Two integrated potentiometers control air temperature door position and blower motor speed. The integrated vacuum system controls the mode door position. The control assembly supports the features as in the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7099 Control Assembly: Service and Repair HVAC CONTROL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP cluster trim plate. 2. Remove the retaining screw from the left edge of the HVAC control assembly. 3. Pivot the HVAC control assembly from the IP. 4. Remove the HVAC control assembly from the IP in order to access the vacuum and the electrical connectors. 5. Disconnect the following items from the HVAC control assembly: - The electrical connectors - The vacuum connectors INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7100 1. Connect the following items to the HVAC control assembly: - The vacuum connectors - The electrical connectors 2. Align the tab on the HVAC control assembly with the slot in the IP. 3. Install the HVAC control assembly to the IP. 4. Install the screw to the HVAC control assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the IP cluster trim plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement O-RING REPLACEMENT REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure - For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). - For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 5. Cap or tape the A/C refrigerant components. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. IMPORTANT: DO NOT reuse O-ring seals. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 7109 6. The O-ring seal must be fully seated. 7. Assemble the A/C components.Refer to the appropriate repair procedure. - For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. - For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 7110 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement SEALING WASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 4. Discard the sealing washer. IMPORTANT: DO NOT reuse sealing washer. INSTALLATION PROCEDURE 1. Inspect the new seal washer for any signs of cracks, cuts, or damage.Do not use a damaged seal washer. IMPORTANT: Flat washer type seals do not require lubrication. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component.The washer must completely bottom against the surface of the fitting. 5. Assemble the remaining A/C refrigerant components.Refer to the appropriate repair procedure. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 7111 A/C line and the A/C component. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7120 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7121 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7127 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7128 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7129 Evaporator Core: Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary Evaporator Core: Service and Repair Evaporator Core - Auxiliary EVAPORATOR CORE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Remove the left body side rear trim panel. 3. Remove the air outlet duct assembly. 4. Disconnect the electrical connectors. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the retaining nut in order to remove the auxiliary evaporator rear tube assembly from the core. 7. Lower the vehicle. 8. Remove the bolts that retain the case to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7132 9. Remove the auxiliary evaporator module assembly from the vehicle. 10. Remove the screws from the case. 11. Separate the case halves. 12. Remove the evaporator core seal. 13. Remove the core from the case. 14. Inspect the gaskets and the seals for damage. 15. Replace the gaskets and the seals. INSTALLATION PROCEDURE 1. Install the evaporator core into the case. 2. Install the evaporator core seal. 3. Reassemble the case halves. 4. Install the auxiliary evaporator module assembly to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7133 5. Install the bolts that retain the case to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (86 lb in). 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Install new seal washers. 8. Install the auxiliary evaporator underbody rear tube assembly to the core with the retaining nut. Tighten Tighten the nut to 10 N.m (86 lb in). 9. Lower the vehicle. 10. Connect the electrical connectors. 11. Install the air outlet duct assembly. 12. Install the left body side rear trim panel. 13. Evacuate and recharge the system. 14. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7134 Evaporator Core: Service and Repair Evaporator Core Replacement EVAPORATOR CORE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Remove the accumulator. 3. Remove the coolant recovery reservoir. 4. Disconnect the electrical connectors. 5. Remove the bypass valve bracket from the outer case. 6. Remove the evaporator tube from the accumulator. 7. Remove the relay bracket. 8. Loosen the evaporator tube nut at the evaporator. 9. Remove the evaporator tube from the evaporator. 10. Remove the screws from the outer evaporator case. 11. Remove the outer case from the module. 12. Remove the screws in order to split the evaporator module in half. 13. Remove the inner case from the module. 14. Remove the evaporator core. INSTALLATION PROCEDURE 1. If replacing the evaporator core, add the PAG oil to the evaporator. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7135 2. Install the evaporator core. 3. Install the inner case to the evaporator module. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the evaporator case screws. Tighten Tighten the screws to 6 N.m (53 lb in). 5. Install the outer case to the evaporator module. 6. Install the screws to the evaporator case. Tighten Tighten the screws to 6 N.m (53 lb in). 7. Install a new O-ring. 8. Install the evaporator tube to the evaporator. 9. Tighten the evaporator tube nut to the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 10. Install the bypass valve bracket to the outer case. 11. Install the relay bracket. 12. Connect the electrical connectors. 13. Install the accumulator. 14. Install the coolant recovery reservoir. 15. Install the air cleaner assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair EXPANSION (ORIFICE) TUBE REPLACEMENT TOOLS REQUIRED - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Remove the evaporator tube from the evaporator. 4. Remove the O-ring seal. 5. Use the J 26549-E in order to remove the orifice tube. 6. If you have difficulty removing a restricted or plugged expansion (orifice) tube, use the following procedure: 6.1. Remove as much of any impacted residue as possible. 6.2. Carefully apply heat with a heat gun (hair dryer, epoxy dryer, or equivalent) approximately 7 mm (0.25 in) from the dimples on the inlet pipe. DO NOT overheat the pipe. NOTE: If the system has a pressure switch near the expansion (orifice) tube location, it should be removed prior to heating the pipe to avoid damage to switch. 6.3. While applying heat, use the J 26549-E in order to remove the orifice tube. 6.4. Use a turning motion along with a push-pull motion in order to loosen the impacted expansion (orifice) tube. 6.5. Remove the expansion (orifice) tube. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 7139 1. Use the J 26549-E in order to install the expansion (orifice) tube. IMPORTANT: Install the shorter screen end of the expansion (orifice) tube into the evaporator first. 2. Install the new O-ring seal. 3. Install the evaporator tube to the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the evaporator tube nut to 28 N.m (20 lb ft). 4. Evacuate and recharge the system. 5. Leak test the fittings of the component using the J 39400-A. 6. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair THERMAL EXPANSION VALVE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the evaporator core. 2. Gently remove the sealer packed around the thermostatic expansion valve (TXV). 3. Remove the clip that retains the capillary tube to the evaporator core. IMPORTANT: Note the mounting location and the orientation of the capillary tube on the evaporator core. 4. Remove the nuts that retain the TXV to the evaporator core. 5. Remove the TXV from the core. INSTALLATION PROCEDURE 1. Install the TXV to the core. 2. Install the nuts that retain the TXV to the evaporator core. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 7143 Tighten the nuts that retain the TXV to the evaporator core to 5 N.m (44 lb in). 3. Install the capillary tube and the retaining clip to the evaporator core. IMPORTANT: Install the retaining clip and the capillary tube in the location and the orientation that was noted during disassembly. 4. Pack the sealer around the TXV as found during disassembly. 5. Install the evaporator core. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Locations > Page 7147 Coolant Bypass Valve Solenoid Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary Heater Control Valve: Service and Repair Coolant Bypass Valve Replacement - Auxiliary COOLANT BYPASS VALVE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. 4. Disconnect the electrical connector from the auxiliary coolant bypass valve (1). 5. Remove the vacuum hose from the auxiliary coolant bypass valve. 6. Remove the bolt that retains the auxiliary coolant bypass valve to the heater assembly. 7. Using the J 38185, reposition the auxiliary heater inlet hose (10) clamp from the auxiliary coolant bypass valve. 8. Remove the auxiliary heater inlet hose (10) from the auxiliary coolant bypass valve. 9. Using the J 38185, reposition the auxiliary outlet heater hose (2) clamp from the auxiliary coolant bypass valve. 10. Remove the auxiliary outlet heater hose (2) from the auxiliary coolant bypass valve. 11. Remove the auxiliary coolant bypass valve (1). INSTALLATION PROCEDURE 1. Install the auxiliary coolant bypass valve (1). 2. Install the auxiliary outlet heater hose (2) to the auxiliary coolant bypass valve. 3. Using the J 38185, reposition the auxiliary inlet heater hose clamp to the auxiliary coolant bypass valve. 4. Install the auxiliary heater outlet hose (10) to the auxiliary coolant bypass valve. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 7150 5. Using the J 38185, reposition the auxiliary heater hose clamp to the auxiliary coolant bypass valve. 6. Install the auxiliary coolant bypass valve to the heater assembly. 7. Install the bolt that retains the auxiliary coolant bypass valve to the heater assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 8. Connect the vacuum hose to the auxiliary coolant bypass valve. 9. Connect the electrical connector to the auxiliary coolant bypass valve. 10. Fill the cooling system. 11. Install the upper fan shroud. 12. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 7151 Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (Without RPO Code C36) HOT WATER BYPASS VALVE REPLACEMENT (WITHOUT RPO CODE C36) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. 4. Disconnect the vacuum hose from the water bypass valve. 5. Using the J 38185, reposition the heater inlet pipe (5) clamp from the water bypass valve. 6. Remove the heater inlet pipe from the water bypass valve. 7. Using the J 38185, reposition the heater outlet pipe (6) clamp from the water bypass valve. 8. Remove the heater outlet pipe from the water bypass valve. 9. Using the J 38185, reposition the heater inlet hose clamp from the water bypass valve. 10. Remove the heater inlet hose from the water bypass valve. 11. Using the J 38185, reposition the heater outlet hose clamp from the water bypass valve. 12. Remove the heater outlet hose from the water bypass valve. 13. Remove the bolt (3) that retains the water bypass valve (4) to the heater assembly. 14. Remove the water bypass valve. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 7152 1. Install the water bypass valve (4) to the heater assembly. 2. Install the bolt (3) that retains the water bypass valve to the heater assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 3. Install the heater outlet hose to the water bypass valve. 4. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve. 5. Install the heater inlet hose to the water bypass valve. 6. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve. 7. Install the heater outlet pipe to the water bypass valve. 8. Using the J 38185, reposition the heater inlet pipe (5) clamp to the water bypass valve. 9. Install the heater inlet pipe to the water bypass valve. 10. Using the J 38185, reposition the heater outlet pipe (6) clamp to the water bypass valve. 11. Connect the vacuum hose to the water bypass valve. 12. Fill the cooling system. 13. Install the upper fan shroud. 14. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 7153 Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (With RPO Code C36) HOT WATER BYPASS VALVE REPLACEMENT (WITH RPO CODE C36) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. 4. Disconnect the vacuum hose from the water bypass valve. 5. Using the J 38185, reposition the heater inlet hose (8) clamp from the water bypass valve. 6. Remove the heater inlet hose (8) from the water bypass valve. 7. Using the J 38185, reposition the heater outlet hose (7) clamp from the water bypass valve. 8. Remove the heater outlet hose (7) from the water bypass valve. 9. Using the J 38185, reposition the heater inlet hose (3) clamp from the water bypass valve. 10. Remove the heater inlet hose (3) from the water bypass valve. 11. Using the J 38185, reposition the heater outlet hose (4) clamp from the water bypass valve. 12. Remove the heater outlet hose (4) from the water bypass valve. 13. Using the J 38185, reposition the auxiliary heater outlet hose clamp from the water bypass valve. 14. Remove the auxiliary heater outlet hose (5) from the water bypass valve. 15. Using the J 38185, reposition the auxiliary heater outlet hose clamp (6) from the water bypass valve. 16. Remove the auxiliary heater outlet hose (10) from the water bypass valve. 17. Remove the bolt that retains the water bypass valve to the heater assembly. 18. Remove the water bypass valve. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Coolant Bypass Valve Replacement - Auxiliary > Page 7154 1. Install the water bypass valve to the heater assembly. 2. Install the bolt (3) that retains the water bypass valve to the heater assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 3. Install the auxiliary heater outlet hose (5) to the water bypass valve. 4. Using the J 38185, reposition the auxiliary heater outlet hose clamp to the water bypass valve. 5. Install the auxiliary heater outlet hose (10) to the water bypass valve. 6. Using the J 38185, reposition the auxiliary heater outlet hose clamp (6) to the water bypass valve. 7. Install the heater outlet hose (4) to the water bypass valve. 8. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve. 9. Install the heater inlet hose (3) to the water bypass valve. 10. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve. 11. Install the heater outlet hose (7) to the water bypass valve. 12. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve. 13. Install the heater inlet hose (8) to the water bypass valve. 14. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve. 15. Connect the vacuum hose to the water bypass valve. 16. Fill the cooling system. 17. Install the upper fan shroud. 18. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 7159 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 7160 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Using the J 38185, reposition the outlet heater hose clamp at the heater core. 3. Remove the outlet heater hose from the heater core. 4. Using the J 38185, reposition the inlet heater hose clamp at the heater core. 5. Remove the inlet heater hose from the heater core. 6. Remove the screws (9) that retain the cover to the heater case assembly. 7. Remove the straps (8) that retain the heater core to the heater case assembly. 8. Remove the heater core (7) from the vehicle. INSTALLATION PROCEDURE 1. Install the heater core to the vehicle. 2. Install the straps that retain the heater core to the heater case assembly. 3. Install the screws that retain the heater core to the heater case assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 7163 Tighten the screws to 2 N.m (18 lb in). 4. Install the inlet heater hose to the heater core. 5. Using the J 38185, reposition the inlet heater hose clamp at the heater core. 6. Install the outlet heater hose to the heater core. 7. Using the J 38185, reposition the outlet heater hose clamp at the heater core. 8. Refill the cooling system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 7164 Heater Core: Service and Repair Heater Core Replacement - Auxiliary HEATER CORE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Remove the body side front lower trim panel. 3. Remove the clamps from the auxiliary heater pipes. 4. Disconnect the auxiliary heater pipes from the auxiliary heater module. 5. Remove the screws and the band clamp from the right side of the heater core. 6. Remove the screw and the band clamp from the left side of the heater core. 7. Remove the heater core from the heater core case. IMPORTANT: Before removing the auxiliary heater module from the vehicle, be sure to place a protective cover on the floor in order to prevent coolant from leaking onto the carpet. 8. Remove the seals from the heater core. INSTALLATION PROCEDURE 1. Install the seals to the heater core. 2. Install the heater core into the heater core case. 3. Install the screw and the band clamp to the left side of the heater core. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws and the band clamp to 2 N.m (18 lb in). 4. Install the screws and the band clamp to the right side of the heater core. Tighten Tighten the screw and the band clamp to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 7165 5. Connect the auxiliary heater pipes from the auxiliary heater module. 6. Install the clamps to the auxiliary heater pipes. 7. Install the body side front lower trim panel. 8. Refill the system with engine coolant. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet Heater Hose: Service and Repair Heating Hoses Replacement - Inlet HEATING HOSES REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. 3. Remove the coolant recovery reservoir. 4. Remove the heater hose support clamp bolt (5). 5. Using the J 38185, reposition the inlet heater hose clamp from the heater core. 6. Remove the inlet heater hose (2) from the heater core. 7. Using the J 38185, reposition the inlet heater hose clamp from the water valve. 8. Remove the inlet heater hose (2) from the water bypass valve. INSTALLATION PROCEDURE 1. Install the inlet heater hose (2) to the water bypass valve. 2. Using the J 38185, reposition the inlet heater hose clamp to the water bypass valve. 3. Install the inlet heater hose (2) to the heater core. 4. Using the J 38185, reposition the inlet heater hose clamp to the heater core. 5. Install the heater hose support clamp to the heater core. 6. Install the heater hose support clamp bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 7170 Tighten Tighten the bolt to 4 N.m (35 lb in). 7. Install the coolant recovery reservoir. 8. Fill the cooling system. 9. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 7171 Heater Hose: Service and Repair Heating Hoses Replacement - Outlet HEATING HOSES REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. 3. Remove the coolant recovery reservoir. 4. Remove the heater hose support clamp bolt (5). 5. Using the J 38185, reposition the outlet heater hose clamp from the heater core. 6. Remove the outlet heater hose (3) from the heater core. 7. Using the J 38185, reposition the outlet heater hose clamp from the water bypass valve. 8. Remove the outlet heater hose (3) from the water bypass valve. INSTALLATION PROCEDURE 1. Install the outlet heater hose (3) to the water bypass valve. 2. Using the J 38185, reposition the outlet heater hose clamp to the water bypass valve. 3. Install the outlet heater hose (3) to the heater core. 4. Using the J 38185, reposition the outlet heater hose clamp to the heater core. 5. Install the heater hose support clamp to the heater core. 6. Install the heater hose support bolt (5). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 7172 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 7. Install the coolant recovery reservoir. 8. Fill the cooling system. 9. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 7173 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Front HEATER PIPE REPLACEMENT - AUXILIARY FRONT REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the front pipes (5) from the rear pipes. 4. Remove the bolts (3) that retain the front pipes (5) to the body. 5. Remove the clips (4) that retain the front pipes (5) to the body. 6. Remove the auxiliary heater front pipes (5) from the heater hoses (1). 7. Remove the auxiliary heater front pipes (5). INSTALLATION PROCEDURE 1. Install the auxiliary heater front pipes (5). 2. Connect the auxiliary heater front pipes (5) to the heater hoses (1). 3. Install the front pipe retaining clips (4) that retains the front pipes (5) to the body. 4. Install the bolts (3) that retain the front pipes (5) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the auxiliary heater front pipes (5) to the rear pipes. 6. Fill the cooling system with engine coolant. 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heating Hoses Replacement - Inlet > Page 7174 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Rear HEATER PIPE REPLACEMENT - AUXILIARY REAR REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Raise the vehicle.Refer to Vehicle Lifting. 3. Disconnect the auxiliary heater rear pipes from the heater core inlet and outlet tubes. 4. Disconnect the auxiliary heater rear pipes from the front pipes. 5. Remove the pipe retainers from the body. 6. Remove the auxiliary heater rear pipes. INSTALLATION PROCEDURE 1. Install the auxiliary heater rear pipes. 2. Install the pipe retainers to the body. 3. Connect the auxiliary heater rear pipes to the front pipes. 4. Connect the rear pipes to the auxiliary heater core inlet and outlet tubes. 5. Refill the cooling system with engine coolant. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Removal COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL TOOLS REQUIRED J 34992 Compressor Holding Fixture 1. Install the compressor onto the J 34992. 2. Remove the pressure relief valve (5) from the rear head of the compressor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal > Page 7179 High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Installation COMPRESSOR PRESSURE RELIEF VALVE INSTALL TOOLS REQUIRED J 43600 ACR 2000 Air Conditioning Service Center 1. Clean the valve seat area on the rear head. 2. Lubricate the O-ring of the new pressure relief valve (5) and the O-ring assembly using new 525 viscosity refrigerant oil. 3. Install the new pressure relief valve (5). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the new valve to 9.0 N.m (6.1 lb ft). 4. Evacuate and recharge the system using the J 39500-B. 5. Leak test the system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal > Page 7180 High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Replacement COMPRESSOR PRESSURE RELIEF VALVE REPLACEMENT TOOL REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant from the system. 3. Clean the valve seat area on the rear head. 4. Remove the pressure relief valve (1). INSTALLATION PROCEDURE 1. Lubricate the O-ring of the new pressure relief valve (1) using new 525 viscosity refrigerant oil. 2. Install the pressure relief valve (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the pressure relief valve to 9 N.m (80 lb in). 3. Evacuate and recharge the refrigerant system. 4. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal > Page 7181 5. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Remove the grille. 4. Remove the engine cover. 5. Remove the compressor hose assembly bolt (2). 6. Remove the compressor hose assembly from the compressor. 7. Remove and discard the old sealing washers. 8. Remove the hose clamp bracket nut (3) from the engine stud. 9. Loosen the compressor hose assembly nut (6) from the condenser. 10. Remove the compressor hose assembly nut (1) from the accumulator. 11. Remove the bolt from the transmission filler tube to the oil indicator tube. 12. Remove transmission filler tube from the throttle cable bracket. 13. Remove the compressor hose assembly from the vehicle. 14. Cap or plug all open connections on the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7186 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. 4. Install the bolt to the transmission filler tube to the oil indicator tube. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 12 N.m (106 lb in). 5. Install new O-rings. 6. Install the compressor hose assembly to the accumulator. 7. Tighten the compressor hose assembly nut at the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 8. Install new O-rings. 9. Install the compressor hose assembly to the condenser. 10. Tighten the compressor hose assembly nut (6). Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 12. Install new sealing washers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7187 13. Install the compressor hose assembly to the compressor. 14. Tighten the compressor hose assembly bolt. Tighten Tighten the bolt to 34 N.m (25 lb ft). 15. Install the engine cover. 16. Install the grille. 17. Evacuate and recharge the system. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7188 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code C60) EVAPORATOR TUBE REPLACEMENT (WITH RPO CODE C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Loosen the evaporator tube nut at the evaporator. 4. Remove the evaporator tube (2) from the evaporator. 5. Remove the O-ring seal. 6. Remove the grille. 7. Loosen the evaporator tube nut at the condenser. 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7189 Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. 7. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7190 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code C69) EVAPORATOR TUBE REPLACEMENT ((WITH RPO CODE C69) TOOLS REQUIRED - J 38778 Door Trim Pad and Garnish Clip Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the accumulator. 3. Remove the grille. 4. Loosen the evaporator tube nut at the evaporator. 5. Remove the evaporator tube (2) from the evaporator. 6. Remove the O-ring seal. 7. Loosen the evaporator tube nut at the condenser. 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. 10. Remove the right front tire. 11. Use the J 38778 to remove the retainers from the splash shield. 12. Remove the splash shield from the wheelhouse. 13. Remove the nut at the auxiliary evaporator tube block fitting. 14. Remove the evaporator tube from the auxiliary evaporator tube. 15. Remove the O-ring seal. 16. Lower the vehicle. 17. Remove the evaporator tube. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7191 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the new O-ring seal. 5. Install the evaporator tube to the evaporator. 6. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Raise the vehicle.Refer to Vehicle Lifting. 8. Install the new O-ring seal. 9. Install the evaporator tube to the auxiliary evaporator tube. 10. Install the auxiliary evaporator tube block fitting nut. Tighten Tighten the nut to 28 N.m (20 lb ft). 11. Install the splash shield to the wheelhouse. 12. Install the retainers to the splash shield. 13. Install the right front tire. 14. Install the accumulator. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the grille. 17. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7192 Hose/Line HVAC: Service and Repair Accumulator Tube Replacement - Auxiliary Side ACCUMULATOR TUBE REPLACEMENT - AUXILIARY SIDE TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7193 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7194 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7195 Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Remove the grille. 4. Remove the engine cover. 5. Remove the compressor hose assembly bolt (2). 6. Remove the compressor hose assembly from the compressor. 7. Remove and discard the old sealing washers. 8. Remove the hose clamp bracket nut (3) from the engine stud. 9. Loosen the compressor hose assembly nut (6) from the condenser. 10. Remove the compressor hose assembly nut (1) from the accumulator. 11. Remove the bolt from the transmission filler tube to the oil indicator tube. 12. Remove transmission filler tube from the throttle cable bracket. 13. Remove the compressor hose assembly from the vehicle. 14. Cap or plug all open connections on the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7196 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. 4. Install the bolt to the transmission filler tube to the oil indicator tube. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 12 N.m (106 lb in). 5. Install new O-rings. 6. Install the compressor hose assembly to the accumulator. 7. Tighten the compressor hose assembly nut at the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 8. Install new O-rings. 9. Install the compressor hose assembly to the condenser. 10. Tighten the compressor hose assembly nut (6). Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 12. Install new sealing washers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7197 13. Install the compressor hose assembly to the compressor. 14. Tighten the compressor hose assembly bolt. Tighten Tighten the bolt to 34 N.m (25 lb ft). 15. Install the engine cover. 16. Install the grille. 17. Evacuate and recharge the system. 18. Leak test the fittings of the component using the J 39400-A. 19. Install the air cleaner. Evaporator Tube Replacement (With RPO Code C60) EVAPORATOR TUBE REPLACEMENT (WITH RPO CODE C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. 3. Loosen the evaporator tube nut at the evaporator. 4. Remove the evaporator tube (2) from the evaporator. 5. Remove the O-ring seal. 6. Remove the grille. 7. Loosen the evaporator tube nut at the condenser. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7198 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. 7. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Evaporator Tube Replacement (With RPO Code C69) EVAPORATOR TUBE REPLACEMENT ((WITH RPO CODE C69) TOOLS REQUIRED - J 38778 Door Trim Pad and Garnish Clip Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the accumulator. 3. Remove the grille. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7199 4. Loosen the evaporator tube nut at the evaporator. 5. Remove the evaporator tube (2) from the evaporator. 6. Remove the O-ring seal. 7. Loosen the evaporator tube nut at the condenser. 8. Remove the evaporator tube (2) from the condenser (4). 9. Remove the O-ring seal. 10. Remove the right front tire. 11. Use the J 38778 to remove the retainers from the splash shield. 12. Remove the splash shield from the wheelhouse. 13. Remove the nut at the auxiliary evaporator tube block fitting. 14. Remove the evaporator tube from the auxiliary evaporator tube. 15. Remove the O-ring seal. 16. Lower the vehicle. 17. Remove the evaporator tube. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). 3. Tighten the evaporator tube nut (3) to the condenser (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the new O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7200 5. Install the evaporator tube to the evaporator. 6. Tighten the evaporator tube nut at the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Raise the vehicle.Refer to Vehicle Lifting. 8. Install the new O-ring seal. 9. Install the evaporator tube to the auxiliary evaporator tube. 10. Install the auxiliary evaporator tube block fitting nut. Tighten Tighten the nut to 28 N.m (20 lb ft). 11. Install the splash shield to the wheelhouse. 12. Install the retainers to the splash shield. 13. Install the right front tire. 14. Install the accumulator. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the grille. 17. Install the air cleaner. Accumulator Tube Replacement - Auxiliary Side ACCUMULATOR TUBE REPLACEMENT - AUXILIARY SIDE TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7201 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7202 Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. Compressor/Condenser Hose Replacement - Auxiliary COMPRESSOR/CONDENSER HOSE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 39400-A Halogen Leak Detector Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7203 REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant. 3. Remove the grille. 4. Remove the engine cover. 5. Raise the vehicle.Refer to Vehicle Lifting. 6. Disconnect the auxiliary evaporator lines nut from the compressor hose assembly. 7. Lower vehicle. 8. Remove the nut that attaches the compressor hose assembly bracket to the engine. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7204 9. Remove the hose clamp bracket nut (3) from the engine stud. 10. Remove the compressor hose assembly bolt from the compressor. 11. Remove the sealing washers from the compressor. 12. Remove the compressor hose assembly nut (6) from the condenser. 13. Remove the compressor hose assembly nut (1) from the accumulator. 14. Remove the compressor hose assembly from the vehicle. 15. Cap or plug all open connections. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7205 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install the compressor hose assembly nut (1) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 48 N.m (35 lb ft). 4. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Install new seal washers to the compressor. 6. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7206 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the nut that attaches the compressor hose assembly bracket to the engine. Tighten Tighten the nut to 5 N.m (44 lb in). 9. Raise the vehicle.Refer to Vehicle Lifting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7207 10. Connect the auxiliary evaporator hose nut to the compressor hose assembly. Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Lower the vehicle. 12. Install the engine cover. 13. Install the grille. 14. Evacuate and recharge the system. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the air cleaner. Evaporator Tube Replacement - Auxiliary Front EVAPORATOR TUBE REPLACEMENT - AUXILIARY FRONT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator front inlet tube from the evaporator inlet tube (2) at the accumulator. 4. Remove the O-ring seal. 5. Remove the bolts (3) that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. 6. Remove the auxiliary evaporator front inlet tube (2) from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7208 1. Install the auxiliary evaporator front inlet tube (2) to the vehicle. 2. Install the bolts that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. 4. Install the auxiliary evaporator front inlet tube (2) to the auxiliary evaporator side inlet tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Lower the vehicle. 6. Evacuate and recharge the system. 7. Leak test the fittings of the component using the J 39400-A. Evaporator Tube Replacement - Auxiliary Rear EVAPORATOR TUBE REPLACEMENT - AUXILIARY REAR TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7209 3. Remove the auxiliary evaporator rear outlet tube from the auxiliary evaporator outlet side tubes. 4. Remove the auxiliary evaporator rear inlet tube from the auxiliary evaporator inlet side tubes. 5. Remove the bolts that retain the clips on the tubes to the body. 6. Remove the nut that retains the tube to the auxiliary evaporator module. 7. Remove the tube from the auxiliary evaporator module. 8. Remove the seal washers. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7210 1. Install the seal washers. 2. Install the tube to the auxiliary evaporator module. 3. Install the nut that retains the tube to the auxiliary evaporator module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 25 N.m (18 lb ft). 4. Install the bolts that retain the clips on the tubes to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Install the auxiliary evaporator rear tube inlet tube to the auxiliary evaporator inlet side tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 6. Install the auxiliary evaporator rear tube outlet tube to the auxiliary evaporator outlet side tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7211 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Evaporator Tube Replacement - Auxiliary Side EVAPORATOR TUBE REPLACEMENT - AUXILIARY SIDE TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator rear tube (3). 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator front tube (2). 6. Remove the O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7212 7. Remove the bolts (1) that retain the clips on the auxiliary side inlet tube (3) to the body. 8. Remove the auxiliary evaporator side inlet tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator side inlet tube (3) to the vehicle. 2. Install the bolts that retain the clips on the auxiliary evaporator side inlet tube (3) to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7213 4. Install the auxiliary evaporator side inlet tube to the auxiliary evaporator front inlet tube (2). Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. 6. Install the auxiliary evaporator side inlet tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. 9. Leak test the fittings of the component using the J 39400-A. Suction Screen Installation SUCTION SCREEN INSTALLATION TOOL REQUIRED J 44551 Suction Screen Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7214 1. Insert J 44551 -6 sizing tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel (1) to J 44551 -5. 4. Install the J 44551 -5 screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551 -5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. IMPORTANT: Correct placement of J 44551 -5 is critical. 6. Remove the J 44551 -5 suction screen tool from the suction hose. 7. Install an A/C refrigerant filter. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7215 IMPORTANT: After a major compressor failure, you should also install an A/C refrigerant filter. 8. Install the J 44551 -1 suction screen notification label. Suction Screen Replacement SUCTION SCREEN REPLACEMENT TOOLS REQUIRED - J 42220 Universal Leak Detection Lamp - J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. 2. Remove the engine cover. 3. Remove the A/C compressor hose assembly bolt. 4. Separate the A/C compressor hose assembly from the A/C compressor. 5. Select the proper size removal tool (1) from J 44551. IMPORTANT: The suction screens are available in 3 different sizes. 6. Remove the suction screen using the J 44551-31 suction screen removal tool. 6.1. Thread the forcing screw into the suction screen. 6.2. Tighten the nut on the forcing screw to remove the suction screen. INSTALLATION PROCEDURE 1. Insert the J 44551-6 sizing tool (1) into the suction hose to select the correct size suction screen. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7216 2. Insert the suction screen into the suction hose. 3. Install the J 44551-3 mandrel (1) to J 44551-5. 4. Install the J 44551-5 suction screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551-5.The suction screen is fully installed when the screen is flush with the end of the suction hose. IMPORTANT: Correct placement of J 44551-5 is critical. 6. Remove the J 44551-5 suction screen tool from the suction hose. 7. Replace the seal washers. 8. Install the A/C compressor hose assembly to the A/C compressor. 9. Install the A/C compressor hose assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 34 N.m(25 lb ft). 10. Evacuate and recharge the A/C system. 11. Leak test the fittings of the component using J 42220. 12. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair HEATER CASE REPLACEMENT (WITH RPO CODE C60) TOOLS REQUIRED - J 38185 Hose Clamp Pliers - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Recover the refrigerant. 3. Using the J 38185 reposition the heater hose clamps from the heater core. 4. Remove the heater hoses from the heater core. 5. Remove the evaporator case from the vehicle. 6. Remove the heater case retaining nuts (2) from the engine compartment. 7. Roll out the instrument panel. 8. Disconnect the electrical connectors. 9. Disconnect the vacuum lines. 10. Remove the heater case (5) from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7220 1. Install the heater case (5) to the vehicle. 2. Connect the vacuum lines. 3. Connect the electrical connectors. 4. Roll the instrument panel upward. 5. Install the heater case retaining nuts (2) to the engine compartment. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 6 N.m (53 lb in). 6. Install the evaporator casing to the vehicle. 7. Connect the heater hoses to the heater core. 8. Using the J 38185 reposition the heater hose clamps to the heater core. 9. Evacuate and recharge the A/C system. 10. Leak test the fittings of the component using the J 39400-A. 11. Fill the engine coolant. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 7225 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 7226 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 2.0 lb. (0.91 kg.) Air Conditioning Refrigerant with Rear A/C .............................................................................................................................................. 3.0 lb. (1.36 kg.) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7229 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant R134a Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7230 Refrigerant: Service Precautions CAUTION: - Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7231 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly,accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the evaporator tube (1) from the vehicle. 2. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. 4. Using a tubing cutter, cut the marked section of the evaporator tube (1). IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 5. Remove the burrs from the evaporator tube (1). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. IMPORTANT: DO NOT install the O-rings (2) in this step. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 7236 9. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing toward the evaporator. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 7237 15. Install the evaporator tube (1) to the vehicle. 16. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 7238 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Remove the air cleaner. 3. Remove the coolant recovery reservoir. 4. Loosen the nuts (4) from the A/C refrigerant filter (1). IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 5. Remove the A/C refrigerant filter from the evaporator tube (1). INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 7239 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter to the evaporator tube (1) with the flow arrow pointing toward the evaporator. 3. Tighten the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Evacuate and recharge the A/C system. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 7240 5. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 6. Install the coolant recovery reservoir. 7. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7247 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil (R-134a system) PAG oil Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 7248 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams A/C High Pressure Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7253 High Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH The A/C system is protected by two pressure switches. The A/C high pressure switch is a two wire normally open switch. The A/C high pressure switch opens the A/C request signal when the A/C line pressure exceeds 3240 kPa (470 psi) + or - 20 psi. This prevents the A/C compressor from operating. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7254 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED - J 5403 Snap Ring Pliers - J 9553-01 O-Ring Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant the system. 3. Clean the control A/C high pressure switch area before removing the snap ring. 4. Disconnect the electrical connector from the A/C high pressure switch (2) in the rear head of the compressor. 5. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. 6. Remove the A/C high pressure switch (2) from the compressor. 7. Remove the old O-ring seal from the A/C high pressure switch cavity using the J 9553-01. 8. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary. INSTALLATION PROCEDURE 1. Lubricate the new O-ring using new 525 viscosity refrigerant oil. IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring is included in a new switch kit. 2. Install the new O-ring into the groove in the switch cavity. 3. Lubricate the control switch housing using new 525 viscosity refrigerant oil. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7255 4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity. 5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove. 6. Evacuate and recharge the system. 7. Leak test the fitting(s) of the repaired or reinstalled components using the J 39400-A. 8. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7259 A/C Low Pressure Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7260 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The powertrain control module (PCM) applies the A/C low pressure switch control signal. The switch will open when the A/C low side pressure reaches 165-179 kPa (24-26 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 2282 kPa (331 psi). This allows the A/C compressor to turn back ON. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7261 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch (1) from the accumulator (3). INSTALLATION PROCEDURE 1. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the new O-ring seal to the switch. 3. Install the A/C low pressure switch (1) to the accumulator (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The blower motor relay that is used on this vehicle is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). 2. Install the screws to the blower motor resistor assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the windshield washers and the coolant reservoir. 4. Connect the electrical connectors. 5. Install the air cleaner. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7269 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center. 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7277 Ambient Temperature Sensor / Switch HVAC: Locations Front End Center Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7278 Front End Center Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7279 Ambient Air Temperature Sensor (DIC) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7280 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the outside air temperature sensor from the center support bracket by sliding the sensor upward. 3. Disconnect the temperature sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the temperature sensor electrical connector. 2. Install the temperature sensor by sliding the sensor downward. 3. Install the radiator grille to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary Blower Motor Switch-A/C Auxiliary Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary > Page 7286 Blower Motor Switch: Diagrams Blower Motor Switch - Heater Auxiliary Blower Motor Switch-Heater Auxiliary Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Motor Switch - A/C Auxiliary > Page 7287 Blower Motor Switch-Heater Auxiliary Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Auxiliary A/C BLOWER MOTOR SWITCH REPLACEMENT - AUXILIARY A/C REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary A/C blower motor switch (2) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 7290 1. Install the auxiliary A/C blower motor switch (2) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 7291 Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Heater Auxiliary BLOWER MOTOR SWITCH REPLACEMENT - HEATER AUXILIARY REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary heat blower motor switch (1) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary A/C > Page 7292 1. Install the auxiliary heat blower motor switch (1) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams A/C High Pressure Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7297 High Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH The A/C system is protected by two pressure switches. The A/C high pressure switch is a two wire normally open switch. The A/C high pressure switch opens the A/C request signal when the A/C line pressure exceeds 3240 kPa (470 psi) + or - 20 psi. This prevents the A/C compressor from operating. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7298 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED - J 5403 Snap Ring Pliers - J 9553-01 O-Ring Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant the system. 3. Clean the control A/C high pressure switch area before removing the snap ring. 4. Disconnect the electrical connector from the A/C high pressure switch (2) in the rear head of the compressor. 5. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. 6. Remove the A/C high pressure switch (2) from the compressor. 7. Remove the old O-ring seal from the A/C high pressure switch cavity using the J 9553-01. 8. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary. INSTALLATION PROCEDURE 1. Lubricate the new O-ring using new 525 viscosity refrigerant oil. IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring is included in a new switch kit. 2. Install the new O-ring into the groove in the switch cavity. 3. Lubricate the control switch housing using new 525 viscosity refrigerant oil. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7299 4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity. 5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove. 6. Evacuate and recharge the system. 7. Leak test the fitting(s) of the repaired or reinstalled components using the J 39400-A. 8. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7303 A/C Low Pressure Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7304 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The powertrain control module (PCM) applies the A/C low pressure switch control signal. The switch will open when the A/C low side pressure reaches 165-179 kPa (24-26 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 2282 kPa (331 psi). This allows the A/C compressor to turn back ON. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7305 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch (1) from the accumulator (3). INSTALLATION PROCEDURE 1. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the new O-ring seal to the switch. 3. Install the A/C low pressure switch (1) to the accumulator (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair VACUUM HOSE HARNESS REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the vacuum supply lines (3) from the cowl panel under the hood. 2. Disconnect the vacuum supply lines (2) from the vacuum harness in the vehicle. 3. Remove the vacuum supply lines harness and grommet (1) from the cowl panel by grasping the grommet at the base and pulling rearward. 4. Remove the vacuum supply harness. INSTALLATION PROCEDURE 1. Install the vacuum supply harness. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair > Page 7309 2. Install the vacuum supply lines harness and grommet (1) to the corner of the cowl panel. 3. Insert the vacuum supply lines harness and grommet to the cowl panel hole, push inward until fully seated. 4. Connect the vacuum supply lines (2) to the vacuum harness. 5. Connect the vacuum supply lines (3) to the cowl panel under the hood. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair VACUUM TANK REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Remove the upper fan shroud. 3. Remove the vacuum hoses from the vacuum tank. 4. Remove the vacuum tank mounting screws. 5. Remove the vacuum tank. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair > Page 7313 1. Install the vacuum tank. 2. Install the vacuum tank mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3 N.m (26 lb in). 3. Install the vacuum hoses to the vacuum tank. 4. Install the upper fan shroud. 5. Install the air cleaner assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION ACCIDENT WITH OR WITHOUT INFLATOR MODULE DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. - Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a collision or deployment of the air bag(s) for conditions less severe than intended. - The steering column -Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Steering Wheel and Column. - The I/P knee bolsters and mounting points -Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - The I/P brackets, braces, etc.- Inspect for bending, twisting, buckling, or any other type of damage. - The seat belts - Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. - The I/P cross car beam - Inspect for bending, twisting, buckling, or any other type of damage. - The I/P mounting points and brackets - Inspect for bending, twisting, buckling, or any other type of damage. - The seats and seat mounting points - Inspect for bending, twisting, buckling, or any other type of damage. ACCIDENT WITH FRONTAL AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving air bag deployment, replace the following components. Inflatable restraint I/P module - Inflatable restraint steering wheel module - Inflatable restraint steering wheel module coil - Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint front end discriminating sensors Perform additional inspections on the following components. Steering wheel module coil and the coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. - Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, and inflatable restraint front end discriminating sensor - Inspect for any damage and repair or replace each component as needed. SENSOR REPLACEMENT GUIDELINES The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7319 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7320 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection - Off Vehicle Notice: Vehicles involved in accidents that result in any of the following kinds of damage or situations, may also have a damaged or misaligned steering column: Frame damage - Major body damage - Sheet metal damage - If the steering column has been impacted - If the supplemental inflatable restraints system was deployed - Check the capsules on the steering column bracket assembly: all must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. If not, the bracket should be replaced if bolted to the jacket assembly. If the bracket is welded to the jacket assembly replace the jacket assembly. Important: If measured dimensions are not within specifications, a new jacket must be installed. Check for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. - Remove the inflatable restraint steering wheel module coil. - Visually inspect steering shaft for sheared injected plastic (1). If steering shaft shows sheared plastic, a new steering shaft must be installed. - Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked in the following manner. Using a dial indicator at the lower end of the steering shaft, have the steering wheel rotated. Runout must not exceed 1.60 mm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7326 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor connector (1) located on the frame crossmember. 7. Disconnect the inflatable restraint front end discriminating sensor connector. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7327 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7328 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 7. Disconnect the I/P module yellow 2-way connector (1). Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7329 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7330 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connector to the inflatable restraint front end discriminating sensor (1) located on the frame crossmember. 2. Install the CPA to the inflatable restraint front end discriminating sensor connector. 3. Install the AIR BAG fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7331 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6 Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7332 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the passenger knee bolster. 5. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7333 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the passenger knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Description and Operation Air Bag Harness: Description and Operation INFLATABLE RESTRAINT WIRING HARNESSES The inflatable restraint wiring harnesses connect the sensing and diagnostic module (SDM), inflator modules, discriminating sensor, and the class 2 serial data circuit together using weather pack connectors. SIR system connectors are yellow in color for easy identification. When repairing SIR system wiring harnesses, follow the proper testing and wiring repair procedures. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations SDM, IP Module, Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7341 Left Front Interior Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7342 Left Front Interior Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7343 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7344 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7345 Air Bag Control Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7346 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7347 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). 10. Repair the fasteners using the following procedure: IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7348 mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the SDM (4) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 12 N.m (106 lb in). 5. Connect the SDM wiring harness connector (2) to the SDM (4). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the CPA (1) to the sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the sensing and diagnostic module (SDM). 9. Install the carpet retaining sill trim molding. 10. Install the driver seat. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Inflatable Restraint Steering Wheel Module - Coil Connector Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7352 Inflatable Restraint Steering Wheel Module Coil Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7353 Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7354 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR System. Refer to SIR Disabling and Enabling Zone 3. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel nut. 4. Note the mark on the steering shaft and the steering wheel to ensure proper alignment during installation. 5. Remove the steering wheel from the steering shaft. 6. On vehicles with a tilt column, pull the tilt lever straight out from the steering column. 7. Remove the tilt lever assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7355 8. Remove 2 TORX(r) head screws (1) from the lower shroud (2). 9. Remove the lower shroud (2). 10. Remove 2 TORX(r) head screws (2) from the upper shroud (1). 11. Remove the upper shroud (1). 12. Remove the wire harness straps from the steering wheel column wire harness. 13. Remove the retaining ring (3). 14. Remove the SIR coil (4) from the steering shaft. 15. If replacing, discard the SIR coil. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7356 1. To install the SIR coil, perform the following procedure: 1.1. Aim the wheels straight ahead. 1.2. Align the block tooth and the centering mark on the race and upper shaft assembly at the 12 o'clock position. 2. If centering is required, follow the instructions on the notice (1) of the coil assembly. Refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. If the SIR coil does not come with a centering tab, you must center the SIR coil. 3. Align the SIR coil assembly (1) with the horn tower on the turn signal cancel cam assembly (2). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7357 4. Slide the new SIR coil (4) onto the steering shaft assembly (2). IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. 5. Firmly seat the retaining ring (3) into the groove on the steering shaft assembly (2). 6. Remove and discard the centering tab from the new SIR coil (4). 7. Install the upper shroud (1) and secure by using 2 TORX(r) head screws (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7358 8. Install the lower shroud (2) and secure by using 2 TORX(r) head screws (1). 9. Verify that the tabs on the lower shroud (1) engage with the tabs on the upper shroud (2). Snap the tabs together. Tighten Tighten the screws to 1.5 N.m (13 lb in). 10. On vehicles with a tilt column, align the tilt lever into the steering column. 11. Slide the tilt lever handle into the steering column until the handle locks into position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7359 12. Feed the wiring through the steering wheel. 13. Align the steering wheel with the mark on the steering shaft. Install the steering wheel onto the shaft. 14. Install the nut for the steering wheel. Tighten Tighten the nut to 41 N.m (30 lb ft). 15. Install the inflatable restraint steering wheel module. 16. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations SDM, IP Module, Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7363 Forward Lamps Harness, Left Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7364 Inflatable Restraint Front End Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7365 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7366 Impact Sensor: Service and Repair INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Refer to SIR Caution in Service Precautions. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Disconnect the inflatable restraint front end discriminating sensor harness connector located at the top of the frame (1). 4. Remove the bolts (2). 5. Remove the inflatable restraint front end discriminating sensor (3) from the cradle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the front end discriminating sensor horizontally to the top of the frame. 3. Point the arrow on the sensor toward the front of the vehicle. 4. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fastener to 6.5 N.m (58 lb in). 5. Perform the following steps in order to complete the first fastener repair: IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7367 5.1. Remove and discard the improperly installed rivet. 5.2. Reattach the sensor with a new rivet. 6. Perform the following steps, if needed, in order to complete a second fastener repair: 6.1. Remove the improperly installed rivet. 6.2. Enlarge the mounting holes in the lower radiator support to 9.0 mm (0.35 in). 6.3. Insert and properly seat the rivnut. 6.4. Install the screw to the sensor. Tighten Tighten fasteners to 6.5 N.m (58 lb in). 7. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 8. Lower the vehicle. Refer to Vehicle Lifting. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verify that the SDM is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition 1 voltage and the IPC flashes the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and request the IPC to turn the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a diagnostic trouble code (DTC) and request the IPC to turn the AIR BAG indicator ON. The presence of a SIR system malfunction could result in non-deployment of the air bags. The AIR BAG indicator will remain ON until the malfunction has been repaired. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation DRIVER AND PASSENGER KNEE BOLSTERS The knee bolsters are designed to help restrain the lower torsos of front seat occupants by absorbing energy through the front seat occupants' upper legs. In a frontal collision the front seat occupants legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damage after a collision. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right Knee Diverter: Service and Repair Knee Bolster Bracket Replacement - Right KNEE BOLSTER BRACKET REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the passenger's knee bolster. 2. Roll the instrument panel down. IMPORTANT: Do not remove the instrument panel to replace right or right center knee bolster brackets. 3. Remove the knee bolster bracket right side screws. 4. Remove the knee bolster bracket right side. 5. Remove the knee bolster bracket right center screws. 6. Remove the knee bolster bracket right center. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7384 1. Install the knee bolster bracket right center. 2. Install the knee bolster bracket right center screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the knee bolster bracket right center screws to 8 N.m (71 lb in). 3. Install the knee bolster bracket right side. Install the knee bolster bracket right side screws. Tighten Tighten the knee bolster bracket right side screws to 8 N.m (71 lb in). 4. Roll the instrument panel up. 5. Install the passenger's knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7385 Knee Diverter: Service and Repair Knee Bolster Bracket Replacement - Left KNEE BOLSTER BRACKET REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the driver's knee bolster. 2. Remove the bolts that retain the brackets to the instrument panel trim pad. 3. Roll the instrument panel back, but do not remove the instrument panel. 4. Remove the bolts that retain the knee bolster brackets to the instrument panel carrier. 5. Remove the knee bolster brackets from the vehicle. INSTALLATION PROCEDURE 1. Install the knee bolster brackets to the vehicle. 2. Install the bolts that retain the brackets to the instrument panel carrier. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to the brackets to the instrument panel carrier to 10 N.m (89 lb in). 3. Install the instrument panel to the vehicle. 4. Install the bolts that retain the brackets to the instrument panel trim pad. Tighten Tighten the bolts that retain the bracket to the instrument panel to 10 N.m (89 lb in). 5. Install the driver's knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7386 Knee Diverter: Service and Repair Knee Bolster Replacement - Left KNEE BOLSTER REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the screws that retain the bolster to the instrument panel. 2. Pull back on the bolster in order to release the two retainers and remove the bolster. 3. Remove the parking brake release lever from the knee bolster. INSTALLATION PROCEDURE 1. Install the parking brake release lever to the knee bolster. 2. Install the knee bolster: 2.1. Align the retainers. 2.2. Press the panel into place. 3. Install the screws that retain the knee bolster to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the knee bolster screws to 8 N.m (71 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7387 Knee Diverter: Service and Repair Knee Bolster Replacement - Right KNEE BOLSTER REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the instrument panel extension. 2. Remove the screws that retain the knee bolster to the instrument panel. 3. Pull back on the knee bolster in order to release the retainers from the instrument panel. 4. Remove the knee bolster. INSTALLATION PROCEDURE 1. Install the knee bolster. 2. Install the knee bolster to the instrument panel: 2.1. Align the retainers. 2.2. Press the panel into place. 3. Install the screws that retain the bolster to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the knee bolster screws to 8 N.m (71 lb in). 4. Install the instrument panel extension. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations SDM, IP Module, Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7392 Left Front Interior Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7393 Left Front Interior Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7394 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7395 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7396 Air Bag Control Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7397 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7398 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). 10. Repair the fasteners using the following procedure: IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7399 mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the SDM (4) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 12 N.m (106 lb in). 5. Connect the SDM wiring harness connector (2) to the SDM (4). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the CPA (1) to the sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the sensing and diagnostic module (SDM). 9. Install the carpet retaining sill trim molding. 10. Install the driver seat. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7405 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor connector (1) located on the frame crossmember. 7. Disconnect the inflatable restraint front end discriminating sensor connector. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7406 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7407 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 7. Disconnect the I/P module yellow 2-way connector (1). Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7408 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7409 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connector to the inflatable restraint front end discriminating sensor (1) located on the frame crossmember. 2. Install the CPA to the inflatable restraint front end discriminating sensor connector. 3. Install the AIR BAG fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7410 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6 Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7411 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the passenger knee bolster. 5. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7412 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the passenger knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT REMOVAL PROCEDURE 1. Inspect the seat belt tether spacer bar hook (1) for damage. If damaged, replace the bucket seat riser spacer bar. 2. The front bucket seat passenger side tether belt (2) runs down the center of seatback and hooks to the seat belt tether spacer bar (4) located in the center of the seat riser. 3. For the bench seats YC6, the tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Page 7417 4. For the bench seats YC7, the seat belt tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. INSTALLATION PROCEDURE 1. For the bench seats YC7, the seat belt tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. 2. For the bench seats YC6, the tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Page 7418 3. The front bucket seat passenger side tether belt (2) runs down the center of seatback and hooks to the seat belt tether spacer bar (4) located in the center of the seat riser support bar. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 7427 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 7433 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) REMOVAL PROCEDURE 1. Remove the seat belt buckle latch bolt from the side of the riser. 2. Remove the seat belt buckle latch. The seat does not have to be removed from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle latch to the side of the riser. 2. Install the seat belt buckle latch bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle latch bolt to the riser to 35 N.m (26 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7436 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP5) REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat belt latch by removing the hog rings and lifting up on the cover to expose the nut. The complete seat cover does not have to be removed. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. 2. Install the seat belt latch nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the seat cover and rehog ring it back in place. 4. Install the rear bench seat to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7437 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP8) REMOVAL PROCEDURE 1. Remove the rear bench seat side cover screw to expose the seat belt latch bolt. 2. Remove the rear bench seat side cover screw. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. 2. Install the seat belt latch nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the rear bench seat side cover and screw. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7438 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Front REMOVAL PROCEDURE 1. Remove the nuts located on the inside of the seat riser. 2. Remove the seat belt buckle from the floor stud by lifting upward on the seat. The seat does not have to be removed from the vehicle. 3. Disconnect the seat belt buckle warning lamp electrical connector. 4. Remove the seat belt buckle. INSTALLATION PROCEDURE 1. Install the seat belt buckle. 2. Connect the seat belt buckle warning electrical connector. 3. Install the seat belt buckle to the floor stud. 4. Install the nuts located at the base of the seat riser. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bucket seat to the floor to 35 N.m (26 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7439 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) REMOVAL PROCEDURE 1. Remove the seat belt buckle latch bolt from the side of the riser. 2. Remove the seat belt buckle latch. The seat does not have to be removed from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle latch to the side of the riser. 2. Install the seat belt buckle latch bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle latch bolt to the riser to 35 N.m (26 lb ft). Seat Belt Buckle and Latch Replacement - Rear (RPO ZP5) REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat belt latch by removing the hog rings and lifting up on the cover to expose the nut. The complete seat cover does not have to be removed. 3. Remove the seat belt latch nut. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7440 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. 2. Install the seat belt latch nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the seat cover and rehog ring it back in place. 4. Install the rear bench seat to the vehicle. Seat Belt Buckle and Latch Replacement - Rear (RPO ZP8) REMOVAL PROCEDURE 1. Remove the rear bench seat side cover screw to expose the seat belt latch bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7441 2. Remove the rear bench seat side cover screw. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. 2. Install the seat belt latch nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the rear bench seat side cover and screw. Seat Belt Buckle Replacement - Front REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7442 1. Remove the nuts located on the inside of the seat riser. 2. Remove the seat belt buckle from the floor stud by lifting upward on the seat. The seat does not have to be removed from the vehicle. 3. Disconnect the seat belt buckle warning lamp electrical connector. 4. Remove the seat belt buckle. INSTALLATION PROCEDURE 1. Install the seat belt buckle. 2. Connect the seat belt buckle warning electrical connector. 3. Install the seat belt buckle to the floor stud. 4. Install the nuts located at the base of the seat riser. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bucket seat to the floor to 35 N.m (26 lb ft). Seat Belt Buckle Replacement - Center Rear REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7443 2. Remove the seat belt buckle retaining bolt from the seat frame. 3. Remove the seat belt buckle through the seat back. INSTALLATION PROCEDURE 1. Install the seat belt buckle through the seat back. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7444 2. Install the seat belt buckle retaining bolt to the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle bolt to the seat frame to 53 N.m (39 lb ft). 3. Install the rear bench seat to the vehicle. Seat Belt Buckle Replacement - Rear REMOVAL PROCEDURE 1. Remove the nuts located on the inside of the seat riser. 2. Remove the seat belt buckle from the floor stud by lifting upward on the seat. The seat does not have to be removed from the vehicle. 3. Remove the seat belt buckle. INSTALLATION PROCEDURE 1. Install the seat belt buckle. 2. Install the seat belt buckle to the floor stud. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7445 3. Install the nuts located at the base of the seat riser. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bucket seat to the floor to 35 N.m (26 lb ft). Seat Belt Buckle and Latch Replacement - No. 2 Rear REMOVAL PROCEDURE 1. Remove the rear seat form the vehicle. 2. Remove the seat belt buckle and latch retaining bolt from the seat frame. 3. Remove the seat belt buckle and latch through the seat back. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) > Page 7446 1. Install the seat belt buckle and latch through the seat back. 2. Install the seat belt buckle and latch retaining bolt to the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle and latch retaining bolt to 53 N.m (39 lb ft). 3. Install the rear bench seat in the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front Seat Belt Guide Track: Service and Repair Shoulder Belt Guide Adjuster Replacement - Front REMOVAL PROCEDURE 1. Remove the cover for the front seat shoulder belt to expose the bolt. 2. Remove the front seat shoulder belt retaining bolt from the guide adjuster bracket. 3. Remove the left front side door lock pillar garnish molding. 4. Remove the right front side door lock pillar garnish molding. 5. Remove the 2 guide adjuster bracket retaining bolts from the pillar. 6. Remove the guide adjuster bracket from the pillar. INSTALLATION PROCEDURE 1. Install the guide adjuster bracket to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 guide adjuster bracket retaining bolts to the pillar. Tighten Tighten the guide adjuster bracket retaining bolts to the pillar to 20 N.m (15 lb ft). 3. Install the left front side door lock pillar garnish molding. 4. Install the right front side door lock pillar garnish molding. 5. Install the shoulder belt retaining bolt to the guide adjuster bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front > Page 7458 Tighten Tighten the front seat shoulder belt retaining bolt to the guide adjuster bracket to 53 N.m (39 lb ft). 6. Install the cover for the front seat shoulder belt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front > Page 7459 Seat Belt Guide Track: Service and Repair Shoulder Belt Guide Adjuster Replacement - Rear REMOVAL PROCEDURE 1. Open the cover on the rear seat shoulder belt to expose the bolt. 2. Remove the rear seat shoulder belt retaining bolt from the guide adjuster bracket. 3. Remove the left rear - C-pillar side garnish molding trim by grasping both the sides and pull rearward. 4. Remove the 2 guide adjuster bracket retaining bolts from the pillar. 5. Remove the guide adjuster bracket from the pillar. INSTALLATION PROCEDURE 1. Install the guide adjuster bracket to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 guide adjuster bracket retaining bolts to the pillar. Tighten Tighten the guide adjuster bracket retaining bolts to the pillar to 20 N.m (15 lb ft). 3. Align the tabs of the C-pillar side garnish molding trim with the openings in the pillar and push inward until fully seated. 4. Install the shoulder belt retaining bolt to the guide adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to the guide adjuster bracket to 53 N.m (39 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front > Page 7460 5. Close the cover on the rear seat shoulder belt bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) Seat Belt Latch: Service and Repair Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat belt latch by removing the hog rings and lifting up on the cover to expose the nut. The complete seat cover does not have to be removed. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. 2. Install the seat belt latch nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the seat cover and rehog ring it back in place. 4. Install the rear bench seat to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7465 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) REMOVAL PROCEDURE 1. Remove the seat belt buckle latch bolt from the side of the riser. 2. Remove the seat belt buckle latch. The seat does not have to be removed from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle latch to the side of the riser. 2. Install the seat belt buckle latch bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle latch bolt to the riser to 35 N.m (26 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7466 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP8) REMOVAL PROCEDURE 1. Remove the rear bench seat side cover screw to expose the seat belt latch bolt. 2. Remove the rear bench seat side cover screw. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. 2. Install the seat belt latch nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the rear bench seat side cover and screw. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7467 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch Replacement - No. 2 Rear REMOVAL PROCEDURE 1. Remove the rear seat form the vehicle. 2. Remove the seat belt buckle and latch retaining bolt from the seat frame. 3. Remove the seat belt buckle and latch through the seat back. INSTALLATION PROCEDURE 1. Install the seat belt buckle and latch through the seat back. 2. Install the seat belt buckle and latch retaining bolt to the seat frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7468 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle and latch retaining bolt to 53 N.m (39 lb ft). 3. Install the rear bench seat in the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7469 Seat Belt Latch: Service and Repair Seat Belt Latch Replacement - Center Rear REMOVAL PROCEDURE 1. Remove the rear seat from the vehicle. 2. Remove the seat belt latch retaining bolts from the seat frame. 3. Remove the seat belt latch retaining bolts from the seat frame. 4. Remove the seat belt latch through the seat back. 5. Remove the seat belt latch from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7470 1. Install the seat belt latch to the vehicle through the seat back. 2. Install the seat belt latch to the vehicle through the seat back. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that hold the seat belt latch to the seat frame. Tighten Tighten the seat belt latch bolts to 53 N.m (39 lb ft). 4. Install the rear seat to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left Seat Belt Retractor: Service and Repair Seat Belt Retractor Reinforcement Replacement - Left REMOVAL PROCEDURE 1. Remove the cover from the rear seat shoulder belt anchor. 2. Remove the bolt retaining the rear seat shoulder belt anchor to the bracket. 3. Remove the rear seat shoulder belt bracket cover. 4. Remove the nut retaining the rear seat shoulder belt bracket to the reinforcement. 5. Remove the headliner. 6. Remove the nuts retaining the rear seat shoulder belt reinforcement to the roof. 7. Remove the bolts retaining the rear seat shoulder belt reinforcement to the roof. 8. Remove the rear seat shoulder belt reinforcement from the roof. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7475 1. Install the rear seat shoulder belt reinforcement to the roof. 2. Install the bolts to retain the rear seat shoulder belt reinforcement to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat shoulder belt reinforcement bolts to 35 N.m (26 lb ft). 3. Install the nuts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement to the roof nuts to 35 N.m (26 lb ft). 4. Install the headliner. 5. Install the nut to retain the rear seat shoulder belt bracket to the reinforcement. Tighten Tighten the rear seat shoulder belt bracket to the reinforcement nut to 35 N.m (26 lb ft). 6. Install the rear seat shoulder belt bracket cover. 7. Install the bolt to retain the rear seat shoulder belt to the bracket. Tighten Tighten the rear seat shoulder belt to the bracket bolt to 30 N.m (22 lb ft). 8. Install the cover to the rear seat shoulder belt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7476 Seat Belt Retractor: Service and Repair Seat Belt Retractor Reinforcement Replacement - Right REMOVAL PROCEDURE 1. Remove the cover from the rear seat shoulder belt. 2. Remove the bolt retaining the rear seat shoulder belt to the bracket. 3. Remove the rear seat shoulder belt bracket cover. 4. Remove the nut retaining the rear seat shoulder belt bracket to the reinforcement. 5. Remove the headliner. 6. Remove the nuts retaining the rear seat shoulder belt reinforcement to the roof. 7. Remove the bolts retaining the rear seat shoulder belt reinforcement to the roof. 8. Remove the rear seat shoulder belt reinforcement from the roof. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7477 1. Install the rear seat shoulder belt reinforcement to the roof. 2. Install the bolts to retain the rear seat shoulder belt reinforcement to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat shoulder belt reinforcement bolts to the roof 35 N.m (26 lb ft). 3. Install the nuts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement nuts to the roof to 35 N.m (26 lb ft). 4. Install the headliner. 5. Install the nut to retain the rear seat shoulder belt bracket to the reinforcement. Tighten Tighten the seat shoulder belt bracket to the reinforcement nut to 35 N.m (26 lb ft). 6. Install the rear seat shoulder belt bracket cover. 7. Install the bolt to retain the rear seat shoulder belt to the bracket. Tighten Tighten the seat shoulder belt bracket to the reinforcement bolt to 30 N.m (22 lb ft). 8. Install the cover to the rear seat shoulder belt bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7478 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Left Front REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the left inside garnish molding. 6. Remove the body side front lower molding. 7. Remove the electrical connectors. 8. Remove the bolt retaining the retractor from the pillar, lift upward to release. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. 2. Install the retractor bolt to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). 3. Install the electrical connectors. 4. Install the body side front lower molding. 5. Install the left inside garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7479 6. Install the bolt retaining the shoulder belt guide to the adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7480 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Right Front REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the right front lock pillar inside garnish molding. 6. Remove the cover on the base of the retractor to expose the bolt. 7. Remove the bolt from the retractor to the pillar. 8. Remove the electrical connectors. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. 2. Install the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retractor bolt to the pillar. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). 4. Install the cover to the base of the retractor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7481 5. Install the bolt retaining the shoulder belt to the guide adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 6. Install the right front lock pillar inside garnish molding. 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7482 Seat Belt Retractor: Service and Repair Seat Belt Retractor Reinforcement Replacement - Left REMOVAL PROCEDURE 1. Remove the cover from the rear seat shoulder belt anchor. 2. Remove the bolt retaining the rear seat shoulder belt anchor to the bracket. 3. Remove the rear seat shoulder belt bracket cover. 4. Remove the nut retaining the rear seat shoulder belt bracket to the reinforcement. 5. Remove the headliner. 6. Remove the nuts retaining the rear seat shoulder belt reinforcement to the roof. 7. Remove the bolts retaining the rear seat shoulder belt reinforcement to the roof. 8. Remove the rear seat shoulder belt reinforcement from the roof. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7483 1. Install the rear seat shoulder belt reinforcement to the roof. 2. Install the bolts to retain the rear seat shoulder belt reinforcement to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat shoulder belt reinforcement bolts to 35 N.m (26 lb ft). 3. Install the nuts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement to the roof nuts to 35 N.m (26 lb ft). 4. Install the headliner. 5. Install the nut to retain the rear seat shoulder belt bracket to the reinforcement. Tighten Tighten the rear seat shoulder belt bracket to the reinforcement nut to 35 N.m (26 lb ft). 6. Install the rear seat shoulder belt bracket cover. 7. Install the bolt to retain the rear seat shoulder belt to the bracket. Tighten Tighten the rear seat shoulder belt to the bracket bolt to 30 N.m (22 lb ft). 8. Install the cover to the rear seat shoulder belt. Seat Belt Retractor Reinforcement Replacement - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7484 REMOVAL PROCEDURE 1. Remove the cover from the rear seat shoulder belt. 2. Remove the bolt retaining the rear seat shoulder belt to the bracket. 3. Remove the rear seat shoulder belt bracket cover. 4. Remove the nut retaining the rear seat shoulder belt bracket to the reinforcement. 5. Remove the headliner. 6. Remove the nuts retaining the rear seat shoulder belt reinforcement to the roof. 7. Remove the bolts retaining the rear seat shoulder belt reinforcement to the roof. 8. Remove the rear seat shoulder belt reinforcement from the roof. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7485 1. Install the rear seat shoulder belt reinforcement to the roof. 2. Install the bolts to retain the rear seat shoulder belt reinforcement to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat shoulder belt reinforcement bolts to the roof 35 N.m (26 lb ft). 3. Install the nuts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement nuts to the roof to 35 N.m (26 lb ft). 4. Install the headliner. 5. Install the nut to retain the rear seat shoulder belt bracket to the reinforcement. Tighten Tighten the seat shoulder belt bracket to the reinforcement nut to 35 N.m (26 lb ft). 6. Install the rear seat shoulder belt bracket cover. 7. Install the bolt to retain the rear seat shoulder belt to the bracket. Tighten Tighten the seat shoulder belt bracket to the reinforcement bolt to 30 N.m (22 lb ft). 8. Install the cover to the rear seat shoulder belt bolt. Seat Belt Retractor Replacement - Left Front Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7486 REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the left inside garnish molding. 6. Remove the body side front lower molding. 7. Remove the electrical connectors. 8. Remove the bolt retaining the retractor from the pillar, lift upward to release. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. 2. Install the retractor bolt to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). 3. Install the electrical connectors. 4. Install the body side front lower molding. 5. Install the left inside garnish molding. 6. Install the bolt retaining the shoulder belt guide to the adjuster bracket. Tighten Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7487 Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Seat Belt Retractor Replacement - Right Front REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the right front lock pillar inside garnish molding. 6. Remove the cover on the base of the retractor to expose the bolt. 7. Remove the bolt from the retractor to the pillar. 8. Remove the electrical connectors. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. 2. Install the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retractor bolt to the pillar. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). 4. Install the cover to the base of the retractor. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7488 5. Install the bolt retaining the shoulder belt to the guide adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 6. Install the right front lock pillar inside garnish molding. 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Seat Belt Retractor Replacement - Left Rear REMOVAL PROCEDURE 1. Remove the left rear bucket seat. 2. Remove the seat belt bolt from the rear floor. 3. Remove the body side trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7489 4. Remove the cover from the shoulder belt to expose the bolt. 5. Remove the shoulder belt retaining bolt from the body side pillar. 6. Remove the retractor bolt from the body side panel. INSTALLATION PROCEDURE 1. Install the retractor bolt to the body side panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retractor bolt to 53 N.m (39 lb ft). 2. Install the shoulder belt bolt to the body side pillar. Tighten Tighten the shoulder belt bolt to the body side pillar to 30 N.m (22 lb ft). 3. Install the cover to the shoulder belt. 4. Install the body side trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7490 5. Install the seat belt bolt to the rear floor. Tighten Tighten the seat belt bolt to the rear floor to 53 N.m (39 lb ft). 6. Install the left rear bucket seat. Seat Belt Retractor Replacement - Right Rear REMOVAL PROCEDURE 1. Remove the trim cover from the rear seat belt retractor, by grasping the sides and pull downward. 2. Remove the seat belt retractor buckle from the latch. 2.1. Locate the red dot in the center of the buckle. 2.2. Insert a small pointed tool in the center of the buckle. 2.3. Push inward for it to release from the latch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7491 3. Remove the rear seat belt retractor nuts from the roof reinforcement. 4. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the rear seat belt retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor nuts to the roof reinforcement panel. Tighten Tighten the seat belt retractor nuts to 35 N.m (26 lb ft). 3. Snap the retractor cover into place. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7492 4. Install the seat belt buckle to the latch. Seat Belt Retractor Replacement - No. 2 Left Rear REMOVAL PROCEDURE 1. Remove the left rear storage trays. Squeeze the storage tray and pull upward to release. 2. Remove the shoulder belt cover to expose the bolt. 3. Remove the shoulder belt retaining bolt from the bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7493 4. Remove the retractor retaining bolt. 5. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. 2. Install the retractor retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retractor retaining bolt to 53 N.m (39 lb ft). 3. Install the shoulder belt retaining bolt to the bracket. Tighten Tighten the shoulder belt retaining bolt to the bracket to 35 N.m (26 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7494 4. Install the retractor retaining bolt. Tighten Tighten the retractor retaining bolt to 53 N.m (39 lb ft). 5. Install the storage trays. Squeeze the storage tray together. Press the storage tray into place. Seat Belt Retractor Replacement - No. 2 Right Rear REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7495 1. Remove the jack storage access door. 2. Remove the storage tray. Squeeze the storage tray from underneath. This will expose the retractor bolt. 3. Remove the retractor retaining bolt. 4. Remove the shoulder belt cover to expose the bolt. 5. Remove the shoulder belt retaining bolt from the bracket. 6. Remove the retractor from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Reinforcement Replacement - Left > Page 7496 1. Install the retractor to the vehicle. 2. Install the bolt retaining the shoulder belt to the bracket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt retaining the shoulder belt to the bracket to 30 N.m (22 lb ft). 3. Install the shoulder belt cover. 4. Install the retractor retaining bolt. Tighten Tighten the retractor retaining bolt to 53 N.m (39 lb ft). 5. Install the storage tray. Squeeze the storage tray together. Press the storage tray into place. 6. Install the jack storage access door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations SDM, IP Module, Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7501 Forward Lamps Harness, Left Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7502 Inflatable Restraint Front End Discriminating Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7503 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7504 Impact Sensor: Service and Repair INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Refer to SIR Caution in Service Precautions. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Disconnect the inflatable restraint front end discriminating sensor harness connector located at the top of the frame (1). 4. Remove the bolts (2). 5. Remove the inflatable restraint front end discriminating sensor (3) from the cradle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the front end discriminating sensor horizontally to the top of the frame. 3. Point the arrow on the sensor toward the front of the vehicle. 4. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fastener to 6.5 N.m (58 lb in). 5. Perform the following steps in order to complete the first fastener repair: IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7505 5.1. Remove and discard the improperly installed rivet. 5.2. Reattach the sensor with a new rivet. 6. Perform the following steps, if needed, in order to complete a second fastener repair: 6.1. Remove the improperly installed rivet. 6.2. Enlarge the mounting holes in the lower radiator support to 9.0 mm (0.35 in). 6.3. Insert and properly seat the rivnut. 6.4. Install the screw to the sensor. Tighten Tighten fasteners to 6.5 N.m (58 lb in). 7. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 8. Lower the vehicle. Refer to Vehicle Lifting. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7534 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7535 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7536 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7537 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7538 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7539 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7540 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7541 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7542 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7543 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7544 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7545 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7546 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7547 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7548 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7549 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7550 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7551 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7552 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7553 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7554 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7555 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7556 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7561 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7562 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7563 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7564 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7565 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7566 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7567 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7568 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7569 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7570 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7571 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7572 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7573 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7578 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7579 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7580 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7597 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7598 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7599 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7600 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7601 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7602 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7603 Retained Accessory Power (RAP) Diagram 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 7604 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its limit. The BCM turns OFF the RAP function and de-energizes the RAP relay when one of the following conditions are met: The BCM senses the opening of any door or the liftgate. - The BCM detects a decrease in battery capacity below a prescribed limit. - The BCM receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The transition from OFF to RUN/ON on the ignition switch. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module energizes the RAP relay. This provides power for the following: DIC - power window control switches - power door lock control switches - steering wheel control switches - radio - outside rearview mirror switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with a Diagnostic System Check - Accessory Delay Module. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1 - 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7607 Steps 3 - 5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit.The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7608 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. VISUAL/PHYSICAL INSPECTION - Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1 - 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7609 Steps 4 - 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7610 Steps 1 - 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Service and Repair Antenna Mast: Service and Repair FIXED ANTENNA MAST REPLACEMENT REMOVAL PROCEDURE 1. Unscrew the antenna mast. NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 2. Remove the antenna mast from the antenna base. INSTALLATION PROCEDURE 1. Install the antenna mast to the antenna base. NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 2. Secure the antenna mast to the antenna base. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the antenna mast to 5.5 N.m (49 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 7628 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 7638 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7643 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7648 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair Antenna - Keyless Entry: Service and Repair KEYLESS ENTRY ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Remove the instrument panel cluster. 3. Disconnect the remote keyless entry antenna (1) from the receiver (2). 4. Remove the remote keyless entry antenna (1) from the carrier. 5. Remove the remote keyless entry antenna from the vehicle. INSTALLATION PROCEDURE 1. Install the remote keyless entry antenna to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Page 7654 2. Install the remote keyless entry antenna (1) to the carrier. 3. Connect the remote keyless entry antenna (1) to the receiver (2). 4. Install the instrument panel cluster. 5. Install the instrument panel cluster trim plate. 6. Reprogram the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Remote Control Door Lock Receiver (RCDLR) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams > Page 7658 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left knee bolster. 2. Disconnect the remote keyless entry antenna (2) from the receiver (5). 3. Disconnect the remote keyless entry electrical connector (4) from the receiver (5). 4. Remove the remote keyless entry module screws from the bracket (3). 5. Remove the remote keyless entry module from the carrier. INSTALLATION PROCEDURE 1. Install the remote keyless entry module to the carrier. 2. Install the remote keyless entry module screws to the bracket (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the remote keyless entry module screws to the bracket (3) to 2 N.m (18 lb in). 3. Connect the remote keyless entry antenna (2) to the receiver (5). 4. Connect the remote keyless entry electrical connector (4) to the receiver (5). 5. Install the left knee bolster. 6. Reprogram the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the 2 halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery (2). INSTALLATION PROCEDURE 1. Install the battery (2) with the positive (+) side down. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 7663 Use one 3 V CR2032 battery (or the equivalent). 2. Close the transmitter case (6, 4). 3. Ensure the seal is in position. Align the 2 halves of the case and snap the two halves together. 4. Synchronize the transmitter. 5. Replace the batteries when the range of the transmitter decreases to less than 7 m (23 ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 7667 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut.When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation SECURITY INDICATOR The SECURITY indicator on the instrument cluster is controlled by the VTD system. The SECURITY indicator bulb is located inside the instrument cluster. The SECURITY indicator is controlled by the body control module through the class 2 data line. The VTD system contained in the BCM commands the instrument cluster to control the SECURITY indicator only when the ignition switch is ON. The VTD system uses the indicator as a malfunction indicator. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Cellular Phone: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7679 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Cellular Phone: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7684 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned Cellular Phone: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 7690 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Cellular Phone: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Cellular Phone: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call Cellular Phone: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 7703 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Cellular Phone: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Cellular Phone: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7719 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7720 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7721 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7722 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7723 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7724 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7727 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 Driver Information Center (DIC) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 Driver/Vehicle Information Display: Electrical Diagrams Driver Information System Diagram Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 7805 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION The driver information center (DIC) consists of a multi-function electronic display placed in the overhead console. The DIC displays the following information: - The vehicle fuel information - The outside temperature - The direction the vehicle is facing The display parameters are cycled, changed, and acknowledged using the following 2 DIC buttons mounted at the side of the driver information center: US/MET: Allows the display to switch between English and Metric units. MODE: Used to toggle between OFF, COMP/TEMP and TRIP. COMP/TEMP COMP: In the Compass Mode, one of eight compass readings (N, NE, E, SE, S, SW, W, and NW) will be displayed to indicate the direction the vehicle is facing. TEMP: In the Temperature Mode, the outside air temperature is displayed in either °C or °F. If the outside air temperature is below 3°C (37°F), the display will toggle between ICE and the current outside air temperature in 8 second increments. TRIP In the Trip Mode, the DIC displays the following information based on class 2 serial data: AVG ECON The DIC displays the average fuel economy since the last reset. AVG SPEED: The DIC displays the average speed since the last reset. FUEL USED: The DIC displays the amount of fuel used since the last reset. INST ECON: The DIC displays the instantaneous fuel economy since the last second of driving. RANGE: The DIC displays the estimated distance that can be travelled with the remaining fuel in the tank, based on the fuel economy for the last few hours of driving. The display format for each mode is indicated in the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 7806 Driver/Vehicle Information Display: Service and Repair DRIVER INFORMATION CENTER MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the overhead console (3). 2. Remove the display lens and the switch plate (1). 3. Disconnect the electrical connectors. 4. Remove the temperature/compass electronic display module (2). INSTALLATION PROCEDURE 1. Install the temperature/compass electronic display module (2). 2. Connect the electrical connectors. 3. Install the display lens and the switch plate (1). 4. Install the overhead console (3). 5. Recalibrate the compass. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7815 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7820 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7825 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7826 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7832 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7849 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7854 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7855 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones > Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications Garage Door Opener Transmitter: Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 7877 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 7878 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 7879 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 7880 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 7881 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 7882 Garage Door Opener Locator View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7935 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7936 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7937 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7938 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7939 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7940 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7941 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7942 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7969 Garage Door Opener Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7970 Garage Door Opener Transmitter: Electrical Diagrams Garage Door Opener Diagram Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 7971 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER DESCRIPTION AND OPERATION The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-servicable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400.Inadvertent power is supplied from the body control module (BCM). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - GARAGE DOOR OPENER Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure to use when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Garage Door Opener in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7974 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener SYMPTOMS - GARAGE DOOR OPENER IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the garage door opener. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Steps 1 - 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7975 Steps 4 - 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement GARAGE DOOR OPENER REPLACEMENT REMOVAL PROCEDURE 1. Release the barbed tab at the center of the access panel. 2. Swing the panel down and forward in order to access the module. 3. Disconnect the electrical connector from the module and switch assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 7978 4. Remove the screws that retain the garage door opener and the switch assembly to the console. 5. Remove the opener and the switch assembly from the console. INSTALLATION PROCEDURE 1. Align the LED indicator with the hole in the access panel when setting the opener into place. 2. Install the opener and the switch assembly to the console. 3. Install the screws that retain the opener and the switch assembly to the console. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the electrical connector to the opener and the switch assembly. 5. Swing the access panel up and rearward in order to close the access panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 7979 6. Snap the barbed tab into place in the console. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 7980 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING - UNIVERSAL GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address this problem. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 7981 Non-Compatible Garage Door Openers NON-COMPATIBLE GARAGE DOOR OPENERS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Page 7982 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7988 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Vehicle Personalization Memory Positioning Systems: Description and Operation Vehicle Personalization VEHICLE PERSONALIZATION PROGRAMMABLE AUTOMATIC DOOR LOCKS (IF EQUIPPED) If the vehicle has power door locks, it is equipped with a feature that enables you to program the power door locks. The vehicle left the factory programmed to automatically lock all doors when the vehicle is shifted out of PARK (P), and all doors unlock when the vehicle is shifted into PARK (P). If the vehicle has a manual transmission, it left the factory programmed to lock all doors when the vehicle speed is greater than 13 km/h (8 mph) for two seconds, and unlock all doors once the key is removed from the ignition. The following instructions detail how to enter the programming mode for the power door lock feature: 1. Begin with the ignition in OFF. Then pull the turn signal/multifunction lever all the way toward you and hold it there while you perform the next step. 2. Turn the key to RUN and OFF twice. Then, with the key in OFF, release the turn signal/multifunction lever. Once you do this, you will hear the lock switch lock and unlock. 3. You are now ready to program the automatic door locks. Select one of the following four programming options and follow the instructions. You will have 30 seconds to complete programming. If you exceed the 30 seconds limit, The locks will automatically lock and unlock to indicate that you have left the program mode. If this occurs, repeat the procedure beginning with step 1. You can exit the program mode any time by turning the ignition to RUN. If the LOCK/UNLOCK switches are not pressed while in the programming mode, the current LOCK/UNLOCK mode will not be modified. The following is a list of available programming options: - All doors lock/Only the driver's door unlocks: Press the lock side of the power door lock switch on the door panel once, and then the unlock side once. - All doors lock/All doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side twice. - All doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side three times. - No doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel twice. This turns off the automatic door lock feature. ADDITIONAL INFORMATION Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Vehicle Personalization > Page 7993 Memory Positioning Systems: Description and Operation Personalization Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization . This vehicle does not have specific driver personalization available. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8002 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8007 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8013 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 8022 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8031 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8032 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8033 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8034 Diagnostic Tips Review Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8035 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8036 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8037 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8038 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8039 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8040 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8041 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8042 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8043 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8044 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8045 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8046 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8047 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8048 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8065 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 8079 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8088 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8089 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8090 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8091 Diagnostic Tips Review Table Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8092 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8093 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8094 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8095 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8096 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8097 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8098 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8099 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8100 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8101 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8102 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8103 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8104 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8105 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Audio Amplifier Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8126 Audio Amplifier Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8127 Audio Amplifier Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8128 Amplifier: Service and Repair AMPLIFIER REPLACEMENT REMOVAL PROCEDURE 1. Remove the body side front lower trim panel. 2. Disconnect the electrical connector from the amplifier. 3. Remove the amplifier from the vehicle by sliding the amplifier toward the rear of the vehicle. INSTALLATION PROCEDURE 1. Align the mounting tabs and slide the amplifier toward the front of the vehicle in order to install the amplifier to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8129 2. Connect the electrical connector to the amplifier. 3. Install the body front lower trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Service and Repair Compact Disc Player (CD): Service and Repair REMOTE CD PLAYER REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel extension trim plate. 2. Squeeze the fasteners on both sides of the remote compact disc player. 3. Pull out the remote compact disc player. 4. Disconnect the electrical connectors. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Align the fasteners on the remote compact disc player with the slots in the instrument panel extension. 3. Slide the remote compact disc player into place until the fasteners are fully seated. 4. Install the instrument panel extension trim plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door Speaker - LF Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8142 Speaker - LF Door Tweeter Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8143 Speaker - LR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8144 Speaker - LR Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8145 Speaker: Diagrams Speaker - LF Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8146 Speaker - LF Door Tweeter Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8147 Speaker - LR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8148 Speaker - LR Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8149 Speaker - LR Subwoofer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8150 Speaker - RF Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8151 Speaker - RF Door Tweeter Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8152 Speaker - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8153 Speaker - RR Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 8154 Speaker - RR Subwoofer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference Speaker Replacement Reference Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8157 Speaker: Service and Repair Speaker Replacement - Front Lower SPEAKER REPLACEMENT - FRONT LOWER REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the mounting screws. 3. Remove the speaker from the door. 4. Disconnect the electrical connector from the speaker. INSTALLATION PROCEDURE 1. Connect the electrical connector to the speaker. 2. Install the speaker to the door. 3. Install the speaker mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the speaker mounting screws to 2 N.m (18 lb in). 4. Verify component operation. 5. Install the door trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8158 Speaker: Service and Repair Speaker Replacement - Front Upper SPEAKER REPLACEMENT - FRONT UPPER REMOVAL PROCEDURE 1. Remove the assist handle from the door. 2. Remove the retaining screw from the trim plate. 3. Remove the escutcheon from the trim plate. 4. Swing the plate down. 5. Remove the tweeter speaker from the trim plate by rotating in order to clear the mounting tabs. 6. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the tweeter speaker to the trim plate by rotating in order to lock the mounting tabs. 3. Verify component operation. 4. Swing the trim plate up. 5. Install the escutcheon to the trim plate. 6. Install the retaining screw to the trim plate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the trim plate screw to 2 N.m (18 lb in). 7. Install the assist handle to the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8159 Speaker: Service and Repair Speaker Replacement - Rear Pillar SPEAKER REPLACEMENT - REAR PILLAR REMOVAL PROCEDURE 1. Gently pry the rear speaker grille from the trim panel using a suitable flat-bladed tool. 2. Remove the speaker mounting screws. 3. Remove the rear speaker from the panel. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the rear speaker to the trim panel. 3. Install the speaker mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the speaker mounting screws to 2 N.m (18 lb in). 4. Verify component operation. 5. Install the rear speaker grille to the trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8160 Speaker: Service and Repair Speaker Replacement Reference Speaker Replacement - Front Lower SPEAKER REPLACEMENT - FRONT LOWER REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the mounting screws. 3. Remove the speaker from the door. 4. Disconnect the electrical connector from the speaker. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8161 1. Connect the electrical connector to the speaker. 2. Install the speaker to the door. 3. Install the speaker mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the speaker mounting screws to 2 N.m (18 lb in). 4. Verify component operation. 5. Install the door trim panel. Speaker Replacement - Front Upper SPEAKER REPLACEMENT - FRONT UPPER REMOVAL PROCEDURE 1. Remove the assist handle from the door. 2. Remove the retaining screw from the trim plate. 3. Remove the escutcheon from the trim plate. 4. Swing the plate down. 5. Remove the tweeter speaker from the trim plate by rotating in order to clear the mounting tabs. 6. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8162 2. Install the tweeter speaker to the trim plate by rotating in order to lock the mounting tabs. 3. Verify component operation. 4. Swing the trim plate up. 5. Install the escutcheon to the trim plate. 6. Install the retaining screw to the trim plate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the trim plate screw to 2 N.m (18 lb in). 7. Install the assist handle to the door. Speaker Replacement - Rear Pillar SPEAKER REPLACEMENT - REAR PILLAR REMOVAL PROCEDURE 1. Gently pry the rear speaker grille from the trim panel using a suitable flat-bladed tool. 2. Remove the speaker mounting screws. 3. Remove the rear speaker from the panel. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8163 1. Connect the electrical connector. 2. Install the rear speaker to the trim panel. 3. Install the speaker mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the speaker mounting screws to 2 N.m (18 lb in). 4. Verify component operation. 5. Install the rear speaker grille to the trim panel. Speaker Replacement - Rear Door SPEAKER REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the rivets that retain the speaker to the door. 3. Disconnect the electrical connector from the speaker. 4. Remove the speaker from the door. INSTALLATION PROCEDURE 1. Position the speaker to the door. 2. Connect the electrical connector to the speaker. 3. Install the speaker to the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8164 4. Use a rivit gun in order to secure the speaker to the door with new rivets. 5. Install the door trim panel. Speaker Grille Replacement - Rear SPEAKER GRILLE REPLACEMENT - REAR REMOVAL PROCEDURE 1. Open the rear door(s). 2. Separate the corners of the grille from the trim panel, one at a time, in order to remove the grille. 3. Remove the grille from the door trim panel. INSTALLATION PROCEDURE 1. Align the grill retaining clips with the slots in the door trim panel. 2. Seat the grille into place. 3. Close the door(s). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair CASSETTE PLAYER CARE AND CLEANING TOOLS REQUIRED J 39916-ACD and Cassette Diagnostic Audio Kit If you do not regularly clean the tape player, the tape player is subject to the following conditions: - Reduced sound quality - Ruined cassettes - A damaged tape mechanism Cassette tapes may not operate properly if they are not stored in their cases away from the following conditions: - Contaminants - Direct sunlight - Extreme heat Cleaning Intervals Clean the cassette tape player after every 15 hours of operation for optimum performance. Clean the cassette tape player at a maximum of every 50 hours of playing time. This will prevent damage to the cassette tape player mechanism. The radio may display CLN, CLEAN, or CLEAN TAPE (depending on the type of radio being used), if equipped with the clean tape indicator feature. This indicates that you have used the tape player for 50 hours without resetting the tape clean timer. If this message appears on the display, clean the cassette tape player. The player can still play tapes but the player should be cleaned as soon as possible in order to prevent damage to the tapes and/or the player. Cassettes are subject to wear and the sound quality may degrade over time. If you notice a reduction in sound quality, play a different cassette. A new cassette may indicate whether the tape or the tape player is at fault. If the sound quality does not improve when the second tape is played, clean the cassette player. Perform this step regardless of when you last cleaned the cassette player. If a noticeable improvement is not achieved after cleaning the player, remove the radio assembly for repair. Head And Capstan Cleaning The following 2 components are cleaned on a cassette player: The head - The capstan IMPORTANT: Do not contact the tape head with magnetized tools. If the head becomes magnetized, every cassette played in the player will be degraded. In order to properly clean a tape player, use the cleaning cassette in J 39916-A in order to clean the head and the capstan. The cleaning cassette is a scrubbing action, non-abrasive cassette with pads which scrub the tape head as the hubs of the cleaner cassette turn. When using a scrubbing action, non-abrasive cleaning, the cassette may eject. The unit is equipped with a cut tape detection feature. The feature than may detected as a broken tape.In order to prevent the cleaning cassette from being ejected, perform the following steps: 1. Turn the ignition switch to one of the following positions (depending upon the vehicle): - ON - RUN - ACC - ACCESSORY 2. Turn OFF the radio. 3. Press and hold the TAPE button for 5 seconds. The tape symbol on the display will flash for 2 seconds. 4. Insert the scrubbing action cleaning cassette. 5. Eject the cleaning cassette after the manufacturer's recommended cleaning time. When the cleaning cassette has been ejected, the cut tape detection feature is active again. The alternative method is to use a non-scrubbing action, wet type cleaning cassette. This cassette uses a fabric belt to clean the tape head. This type of cleaning cassette does not eject on its own. A non-scrubbing action cassette may not clean as thoroughly as the scrubbing type cleaning cassette. The use of this cassette is not recommended. After you clean the player, press and hold the EJECT button for 5 seconds to reset the CLEAN indicator. The radio display shows that the indicator has been reset. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8211 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8213 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8214 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8215 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8216 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8217 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8218 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8219 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8220 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8221 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8222 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8223 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8230 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8231 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8232 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8233 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8234 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8235 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8236 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8237 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8238 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8239 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8240 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8241 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8242 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8243 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8244 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8245 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8246 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8247 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8248 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8249 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8250 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8251 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8252 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8253 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8254 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8255 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8256 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8257 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8258 Retained Accessory Power (RAP) Diagram 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 8259 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its limit. The BCM turns OFF the RAP function and de-energizes the RAP relay when one of the following conditions are met: The BCM senses the opening of any door or the liftgate. - The BCM detects a decrease in battery capacity below a prescribed limit. - The BCM receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The transition from OFF to RUN/ON on the ignition switch. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module energizes the RAP relay. This provides power for the following: DIC - power window control switches - power door lock control switches - steering wheel control switches - radio - outside rearview mirror switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with a Diagnostic System Check - Accessory Delay Module. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1 - 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8262 Steps 3 - 5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit.The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8263 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. VISUAL/PHYSICAL INSPECTION - Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1 - 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8264 Steps 4 - 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8265 Steps 1 - 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8274 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8279 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8284 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8285 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8291 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8308 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8313 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8314 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8336 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8337 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8338 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8344 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8345 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8346 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8355 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8356 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8357 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 8363 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 8364 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 8365 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Passlock(TM) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 8370 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut.When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair Towing Information: Service and Repair TOWING A TRAILER Caution: The driver can lose control when pulling a trailer if the correct equipment is not used or the vehicle is not driven properly. For example, if the trailer is too heavy, the brakes may not work well or even at all. The driver and passengers could be seriously injured. The vehicle may also be damaged; the resulting repairs would not be covered by the vehicle warranty. WEIGHT OF THE TRAILER Two-Wheel Drive Cargo (3.42 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5300 lbs (2406 kg) GCWR ........................ .............................................................................................................................................................. ................ 9500 lbs (4313 kg) Cargo (3.73 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5800 lbs (2633 kg) GCWR ........................ .............................................................................................................................................................. .............. 10000 lbs (4540 kg) Passenger (3.42 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 4900 lbs (2225 kg) GCWR ................ .............................................................................................................................................................. ........................ 9500 lbs (4313 kg) Passenger (3.73 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 5400 lbs (2452 kg) GCWR ................ .............................................................................................................................................................. ...................... 10000 lbs (4540 kg) All-Wheel Drive Cargo (3.42 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5100 lbs (2315 kg) GCWR ........................ .............................................................................................................................................................. ................ 9500 lbs (4313 kg) Cargo (3.73 axle ratio) Maximum trailer weight ................................................................................... ......................................................................................... 5600 lbs (2542 kg) GCWR ........................ .............................................................................................................................................................. .............. 10000 lbs (4540 kg) Passenger (3.42 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 4600 lbs (4088 kg) GCWR ................ .............................................................................................................................................................. ........................ 9500 lbs (4313 kg) Passenger (3.73 axle ratio) Maximum trailer weight ........................................................................... ................................................................................................. 5100 lbs (2315 kg) GCWR ................ .............................................................................................................................................................. ...................... 10000 lbs (4540 kg) NOTE: Maximum trailer weight is calculated assuming the driver and one passenger are in the tow vehicle and it has all the required trailering equipment. The weight of additional optional equipment, passengers and cargo in the tow vehicle must be subtracted from the maximum trailer weight. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the hitch from the frame nuts. 3. Remove the hitch to frame bolts. 4. Remove the hitch and bumper from the vehicle. 5. Remove the hitch to bumper nuts. 6. Remove the hitch to bumper bolts. 7. Remove the hitch from the bumper. Installation Procedure 1. Install the hitch to the bumper. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the hitch to bumper bolts. Tighten the hitch to bumper bolts to 35 N.m (26 lb ft). 3. Install the hitch to bumper nuts. Tighten the hitch to bumper nuts to 25 N.m (18 lb ft). 4. Install the hitch and the bumper to the vehicle. 5. Install the hitch to frame nuts. Tighten the hitch to frame nuts to 60 N.m (44 lb ft). 6. Install the hitch to frame bolts. Tighten the hitch to frame bolts to 55 N.m (41 lb ft). 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Locations View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 8387 Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 8388 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 8389 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 8390 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 8391 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module C1 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8394 Body Control Module C1 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8395 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8396 Body Control Module C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8397 Body Control Module C2 Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8398 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module C3 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8399 Body Control Module C3 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Page 8400 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the RUN position. - The DLC is accessible. - All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 8403 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control.Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 8404 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 8405 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The Scan Tool 9. Perform the body control module programing. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures Access Cover: Procedures Engine Cover ENGINE COVER Removal Procedure 1. Remove the instrument panel extension. Refer to "Instrument Panel Extension". 2. Remove the floor air outlet duct. Refer to "Air Outlet - Center Floor". 3. Remove the bolts from the brackets: ^ Loosen the bolt. ^ Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8410 6. Remove the engine cover. Installation Procedure 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. 3. Install the latch screws. Tighten Tighten the latch screws to 4 Nm (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten Tighten the engine cove bolt to 25 Nm (18 lb ft). 5. Insert the floor air outlet duct. 6. Insert the instrument panel extension. Instrument Panel (IP) Extension INSTRUMENT PANEL (I/P) EXTENSION REPLACEMENT REMOVAL PROCEDURE 1. Remove the caps that cover the extension screws. 2. Remove the screws from the extension. 3. Remove the nuts at the bottom of the extension. 4. Pull toward the rear of the vehicle in order to remove the extension from the instrument panel. 5. Disconnect the electrical connectors. INSTALLATION PROCEDURE 1. Connect the electrical connectors. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8411 2. Install the extension to the instrument panel: 2.1. Align the retainers. 2.2. Press the extension into place until the retainers are seated. 3. Install the nuts that retain the extension to the floor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts that retain the extension to the floor to 8 Nm (71 lb in). 4. Install the retaining screws. Tighten Tighten the screws to 8 Nm (71 lb in). 5. Install the extension screw covers. Air Outlet - Center Floor AIR OUTLET REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE 1. Remove the IP extension. Refer to "Instrument Panel (I/P) Extension". 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. Refer to "Seat Replacement Bucket". 4. Remove the front section of the carpet, if equipped. Refer to "MAT/Carpet Replacement". Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8412 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE 1. Install the floor air outlet to the ducts to the rear seat, if equipped. 2. Install the retaining nuts to the floor outlet duct, if equipped. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8413 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 Nm (18 lb in). 3. Install the front section of the carpet, if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct from the air distributor. 6. Install the IP extension. Engine Cover Guide Assembly ENGINE COVER GUIDE ASSEMBLY Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement. 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly from the vehicle. Installation Procedure 1. Install the engine cover guide assembly. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten Tighten the bolts that retain the engine cover guide to 8.5 Nm (75 lb in). 3. Install the engine cover. MAT/Carpet Replacement MAT/CARPET REPLACEMENT - FRONT FLOOR REMOVAL PROCEDURE 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket. 2. Remove the engine cover, if required. Refer to Engine Cover Replacement. 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement. 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8414 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 9. Remove the carpet/mat from the vehicle. INSTALLATION PROCEDURE CAUTION: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. NOTICE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. TIGHTEN Screws to 2 Nm (18 lb. in.). 4. Install the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement. 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. 7. Install the engine cover, if required. Refer to Engine Cover Replacement. 8. Install the seats and the risers. Refer to Seat Replacement - Bucket in Seats. Seat Replacement - Bucket SEAT REPLACEMENT - BUCKET REMOVAL PROCEDURE 1. Remove the seat belt from the side of the seat belt guide. 2. Remove the nuts that retain the seat to the floor. 3. Disconnect the electrical connector from the power seat if equipped. 4. Remove the seat and the riser from the vehicle. 5. Remove the seat belt guide from the seat riser. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8415 6. Remove the bolts that retain the seat to the riser. 7. Remove the power seat from the seat risers if equipped. 8. Remove the manual seat adjuster wire from the seat tracks. 9. Remove the seat riser spacer nuts and bolts from the seat tracks. 10. Remove the seat riser spacer from the seat risers. INSTALLATION PROCEDURE 1. Install the seat riser spacer to the seat risers. 2. Install the seat riser spacer nuts and bolts to the seat tracks. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat riser spacer nuts and bolts to the seat tracks to 30 Nm (22 lb ft). 3. Install the manual seat adjuster wire to the seat tracks. 4. Install the power seat to the seat risers if equipped. 5. Install the seat belt guide to the seat riser. 6. Install the nuts that retain the seat to the risers. Tighten Tighten the nuts that retain the seat to the riser to 43 Nm (32 lb ft). 7. Install the seat and the seat riser in the vehicle. 8. Connect the electrical connector to the power seat if equipped. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8416 9. Install the nuts that retain the seat to the floor. Tighten Tighten the nuts that retain the seat to the floor to 43 Nm (32 lb ft). 10. Install the seat belt to the side of the seat belt guide. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8417 Access Cover: Removal and Replacement Engine Cover Replacement Engine Cover Replacement Removal Procedure 1. Remove the instrument panel extension. Refer to Instrument Panel (I/P) Extension Replacement (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel, Gages, and Console/Instrument Panel (I/P) Extension Replacement) in Instrument Panel, Gages and Console. 2. Remove the floor air outlet duct. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. 3. Remove the bolts from the brackets: 1. Loosen the bolt. 2. Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. 6. Remove the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8418 Installation Procedure 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the latch screws. Tighten the latch screws to 4 N.m (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten the engine cover bolt to 25 N.m (18 lb ft). 5. Insert the floor air outlet duct. Refer to Instrument Panel (I/P) Extension Replacement (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel, Gages, and Console/Instrument Panel (I/P) Extension Replacement) in Instrument Panel, Gages and Console. 6. Insert the instrument panel extension. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. Engine Cover Guide Replacement Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8419 Engine Cover Guide Replacement Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly. Installation Procedure 1. Install the engine cover guide assembly. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten the bolts that retain the engine cover guide to 8.5 N.m (75 lb in). 3. Install the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front Auxiliary Step / Running Board: Service and Repair Assist Step Extension Replacement - Front Assist Step Extension Replacement - Front Removal Procedure 1. Remove the screws from the front edge of the assist step. Open the door to expose the inner screw. 2. Remove the push clips from the front edge of the assist step. 3. Raise the vehicle to a suitable height. 4. Remove the nut from the front lower corner of the assist step. 5. Remove the assist step pad nuts. 6. Remove the assist step pad. 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it fully releases from the assist step plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8424 7. Remove the front section of the assist step as follows: 1. Lift in the center of the assist step. 2. Slide the front section forward. 3. Lift upward on the assist step to release from the retainer. 8. Remove the nut and bolt (1) from the front assist step support bracket to the pinchweld flange. 9. Remove the assist step support bracket bolts (2) from the underbody. 10. Remove the assist step support bracket. Installation Procedure 1. Install the assist step support bracket. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step support bracket bolts (2) to the underbody . Tighten the assist step support bracket bolts (2) to the underbody to 25 N.m (18 lb ft). 3. Install the nut and bolt (1) to the assist step support bracket and to the pinchweld flange. Tighten the nut and bolt (1) to the assist step support bracket and to the pinchweld flange to 10 N.m (89 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8425 4. Use the following procedure when installing the assist step: 1. Check the fit to the step well and the door opening. 2. Check the height and the alignment to rocker panel. 3. Check the alignment to the cladding and to the body. 4. Check the gaps between the wheel well moldings. 5. Check the lower edge of the assist step to ensure a even gap along the door edge and the body. 6. Install the front section of the assist step to fit over the rear section. Align both sections before installing the nuts to the assist step pad. 5. Install the assist step pad to assist step. Align the assist step pad to the assist step and press downward until fully seated. 6. Install the nuts to the assist step pad by hand. Tighten the nuts to the assist step pad to 2 N.m (18 lb in). 7. Install the nut to the front lower corner of the assist step. Tighten the nut to the front lower corner of the assist step to 10 N.m (89 lb in). 8. Lower the vehicle to a suitable height. 9. Install the push clips to the front edge of the assist step. 10. Install the screws to the front edge of the assist step. Open the door to expose the inner screw. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8426 Tighten the screws to the upper and inner edges of the assist step to 2 N.m (18 lb in). 11. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8427 Auxiliary Step / Running Board: Service and Repair Assist Step Plate Replacement Assist Step Plate Replacement Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 3. Remove the nuts that attach the assist step plate to the assist step support bracket. 4. Remove the assist step plate. Installation Procedure 1. Install the assist step plate. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts that attach the assist step plate to the support bracket. Tighten the nuts that attach the assist step plate to the support bracket to 10 N.m (89 lb in). 3. Install the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8428 Auxiliary Step / Running Board: Service and Repair Assist Step Support Brace Replacement Assist Step Support Brace Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step brace. 2. Remove the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. 3. Remove the assist step brace. Installation Procedure 1. Install the assist step brace. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts and bolts (1) that attach the assist step brace to the assist step support bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step support bracket to 10 N.m (89 lb in). 3. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8429 Auxiliary Step / Running Board: Service and Repair Assist Step Support Bracket Replacement Assist Step Support Bracket Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step support bracket. 2. Remove the nuts that attach the assist step plate to the assist step support bracket. 3. The assist step support brackets are to be numbered 1 through 5 in the order when removing. 4. Remove the nuts and bolts (1) that attach the assist step plate to the assist step bracket. 5. Remove the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. 6. Remove the assist step support bracket from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8430 1. Install the assist step support bracket to the vehicle. 2. Install the assist step support brackets 1 through 5 in the order which they were removed. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. Tighten the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody to 25 N.m (18 lb ft). 4. Install the nuts and bolts (1) that attach the assist step brace to the assist step bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step bracket to 10 N.m (89 lb in). 5. Install the nuts that attach the assist step plate to the assist step support bracket. Tighten the nuts that attach the assist step plate to the assist step support bracket to 10 N.m (89 lb in). 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8431 Auxiliary Step / Running Board: Service and Repair Assist Step Extension Replacement - Front Assist Step Extension Replacement - Front Removal Procedure 1. Remove the screws from the front edge of the assist step. Open the door to expose the inner screw. 2. Remove the push clips from the front edge of the assist step. 3. Raise the vehicle to a suitable height. 4. Remove the nut from the front lower corner of the assist step. 5. Remove the assist step pad nuts. 6. Remove the assist step pad. 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it fully releases from the assist step plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8432 7. Remove the front section of the assist step as follows: 1. Lift in the center of the assist step. 2. Slide the front section forward. 3. Lift upward on the assist step to release from the retainer. 8. Remove the nut and bolt (1) from the front assist step support bracket to the pinchweld flange. 9. Remove the assist step support bracket bolts (2) from the underbody. 10. Remove the assist step support bracket. Installation Procedure 1. Install the assist step support bracket. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step support bracket bolts (2) to the underbody . Tighten the assist step support bracket bolts (2) to the underbody to 25 N.m (18 lb ft). 3. Install the nut and bolt (1) to the assist step support bracket and to the pinchweld flange. Tighten the nut and bolt (1) to the assist step support bracket and to the pinchweld flange to 10 N.m (89 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8433 4. Use the following procedure when installing the assist step: 1. Check the fit to the step well and the door opening. 2. Check the height and the alignment to rocker panel. 3. Check the alignment to the cladding and to the body. 4. Check the gaps between the wheel well moldings. 5. Check the lower edge of the assist step to ensure a even gap along the door edge and the body. 6. Install the front section of the assist step to fit over the rear section. Align both sections before installing the nuts to the assist step pad. 5. Install the assist step pad to assist step. Align the assist step pad to the assist step and press downward until fully seated. 6. Install the nuts to the assist step pad by hand. Tighten the nuts to the assist step pad to 2 N.m (18 lb in). 7. Install the nut to the front lower corner of the assist step. Tighten the nut to the front lower corner of the assist step to 10 N.m (89 lb in). 8. Lower the vehicle to a suitable height. 9. Install the push clips to the front edge of the assist step. 10. Install the screws to the front edge of the assist step. Open the door to expose the inner screw. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8434 Tighten the screws to the upper and inner edges of the assist step to 2 N.m (18 lb in). 11. Lower the vehicle. Assist Step Plate Replacement Assist Step Plate Replacement Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 3. Remove the nuts that attach the assist step plate to the assist step support bracket. 4. Remove the assist step plate. Installation Procedure 1. Install the assist step plate. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts that attach the assist step plate to the support bracket. Tighten the nuts that attach the assist step plate to the support bracket to 10 N.m (89 lb in). 3. Install the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 4. Lower the vehicle. Assist Step Support Brace Replacement Assist Step Support Brace Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step brace. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8435 2. Remove the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. 3. Remove the assist step brace. Installation Procedure 1. Install the assist step brace. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts and bolts (1) that attach the assist step brace to the assist step support bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step support bracket to 10 N.m (89 lb in). 3. Lower the vehicle. Assist Step Support Bracket Replacement Assist Step Support Bracket Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step support bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8436 2. Remove the nuts that attach the assist step plate to the assist step support bracket. 3. The assist step support brackets are to be numbered 1 through 5 in the order when removing. 4. Remove the nuts and bolts (1) that attach the assist step plate to the assist step bracket. 5. Remove the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. 6. Remove the assist step support bracket from the vehicle. Installation Procedure 1. Install the assist step support bracket to the vehicle. 2. Install the assist step support brackets 1 through 5 in the order which they were removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8437 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. Tighten the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody to 25 N.m (18 lb ft). 4. Install the nuts and bolts (1) that attach the assist step brace to the assist step bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step bracket to 10 N.m (89 lb in). 5. Install the nuts that attach the assist step plate to the assist step support bracket. Tighten the nuts that attach the assist step plate to the assist step support bracket to 10 N.m (89 lb in). 6. Lower the vehicle. Assist Step Support Retainer Replacement Assist Step Support Retainer Replacement Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the assist step extension. Refer to Assist Step Replacement (See: Assist Step Replacement) . Important: Do not use a sharp tool in the removal of the assist step retainer, It will damage the paint. Use a plastic tool to assist in the removal of the assist step retainer. 3. Remove the assist step retainer screws from the rocker panel. 4. Insert a plastic tool along the edge of the retainer to aid in the removal. 5. Remove the assist step retainer. The right side is a one piece retainer, the left side is a two piece retainer. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8438 1. Install the assist step retainer to the rocker panel. The right side is a one piece retainer, the left side is a two piece retainer . 1. Clean the rocker panel with isopropyl cleaner or equivalent to remove all of the old double back tape. 2. Remove the strip from the double sided adhesive tape. 3. Align the assist step retainer to the rocker panel and press firmly in place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step retainer screws to the rocker panel. Tighten the assist step retainer screws to the rocker panel to 2 N.m (18 lb in). 3. Install the assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 4. Lower the vehicle. Assist Step Rear Anchor Replacement Assist Step Rear Anchor Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step does not have to be removed to replace the assist step support bracket. 2. Remove the nuts that attach the assist step plate to the assist step support bracket. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8439 3. Remove the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. 4. Remove the nuts and bolts that attach the rear assist step support bracket to the in rocker panel. 5. Remove the assist step support bracket from the vehicle. 6. Remove the nuts and bolts from the rear anchor that attach to the inner pinchwell flange and to the inner rocker panel. 7. Remove the rear anchor from the vehicle. Installation Procedure 1. Install the rear anchor to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8440 2. Install the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel. Tighten the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel to 25 N.m (18 lb ft). 3. Install the assist step support bracket to the vehicle. 4. Install the nuts and bolts that attach the rear assist step support bracket to the inner rocker panel. Tighten the nuts and bolts that attach the rear assist step support bracket to the inner rocker panel to 25 N.m (18 lb ft). 5. Install the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. Tighten the nuts and bolts (1) that attach the assist step brace to the assist step support bracket to 10 N.m (89 lb in). 6. Install the nuts and bolts that attach the assist step plate to the assist step support bracket. Tighten the nuts and bolts that attach the assist step plate to the assist step support bracket to 10 N.m (89 lb in). 7. Lower the vehicle. Assist Step Replacement Assist Step Replacement Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8441 Removal Procedure 1. Remove the screws from the front edge of the assist step extension. Open the door to expose the inner screw. 2. Remove the push clips from the front edge of the assist step extension. 3. Raise the vehicle to a suitable height. 4. Remove the nut from the front lower corner of the assist step extension. 5. Remove the assist step pad nuts. 6. Remove the assist step pad. 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it is fully released from the assist step plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8442 7. Remove the front section of the assist step extension as follows: 1. Lift in the center of the assist step extension. 2. Slide the front section forward. 3. Lift upward on the assist step extension to release it from the retainer and assist plate. 8. Remove the screws from the right rear inner and outer wheel well. Open the sliding door to expose the inner screw. 9. Remove the screws from the rear outer edge of the assist step extension. If the vehicle is equipped with assist steps, the cladding is shorter on the left side (bottom edge). 10. Remove the rear section of the assist step extension, by lifting upward until fully released from the retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8443 11. Remove the nuts that attach the assist step plate to the assist step support bracket . 12. Remove the bolt (1) from the assist step support brace. 13. The assist step support brackets are to be numbered (1, 2, 3, 4, 5) when removing. 14. Remove the bolts (2) from the underbody. 15. Remove the assist step support bracket . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8444 16. Remove the nuts and bolts from the rear assist step support bracket. 17. Remove the rear assist step support bracket. 18. Remove the nuts and bolts from the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel. Important: Do not use a sharp tool in the removal of the assist step retainer, it will damage the paint. Use a plastic tool to assist in the removal of the assist step retainer. The assist step retainer is held in place by a double backing tape. 19. Remove the screws from the assist step retainer. The right side is a one piece retainer, the left side is a two piece retainer. 20. Remove the assist step retainer from the rocker panel. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8445 1. Install the assist step retainer to the rocker panel. The right side is a one piece retainer, the left side is a two piece retainer. 1. Clean the rocker panel with isopropyl cleaner or equivalent to remove all of the old double backing tape. 2. Remove the strip from the double back tape if replacing retainer. 3. Align the assist step retainer to the holes in the rocker panel and press in place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws to the assist step retainer. Tighten the screws to the assist step retainer to 2 N.m (18 lb in). 3. Install the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel. Tighten the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel to 25 N.m (18 lb ft). 4. Install the rear assist step support bracket. 5. Install the nuts and bolts to the rear assist step support bracket. Tighten the nuts and bolts to rear assist step support bracket to 25 N.m (18 lb ft). 6. Lay out the assist step support brackets in the order in which they were removed (1, 2, 3, 4, 5). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8446 7. Install the assist step support brackets and bolts (2) to the underbody. Tighten the assist step support bracket and bolts (2) to the underbody to 25 N.m (18 lb ft). 8. Install the bolt from the inside of the pinchweld flange. 9. Install the assist step support brace bolt (1) to the pinchweld flange. Tighten the assist step support brace bolt (1) to the pinchweld flange to 10 N.m (89 lb in). 10. Install the nuts that attach the assist step plate to the support bracket . Tighten the nuts that attach the assist step plate to the support bracket to 10 N.m (89 lb in). 11. When installing the assist step, check the height and the alignment to rocker panel, cladding and to the body. 12. Install the rear section of the assist step extension. Align the rear edge of assist step extension with the rear edge of the retainer and pushing downward until fully seated. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8447 13. Install the screws to the rear outer edge of the assist step extension. If the vehicle is equipped with running boards, the cladding will be shorter on the left side only. Tighten the screws to the rear outer edge of the assist step extension to 2 N.m (18 lb in). 14. Install the screws to the right rear inner and outer wheel well. Open the sliding door to expose the inner screw. Tighten the screws to the right rear inner and outer wheel well to 2 N.m (18 lb in). Important: Use the following steps when installing the assist step extensions to the retainer: * Check to ensure that the front assist step extension fits over the center of the rear extension. * Check for a suitable fit to the step well and the door opening. * Check the height and the alignment to the rocker panel and to the door opening. * Check the alignment to the cladding and to the body. * Check the alignment gaps between the wheel well molding and body. * Check the lower edge of the assist step extensions to ensure an even gap along the lower edge of the body. 15. Install the assist step extensions to the retainer. 16. Install the nut to the front lower corner of the assist step extension. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8448 Tighten the nut to the front lower corner of the assist step extension to 10 N.m (89 lb in). 17. Lower the vehicle to a suitable height. 18. Install the screws to the front assist step extension. Open the door to expose the inner screw. Tighten the front assist step extension screws to 2 N.m (18 lb in). 19. Install the push clips to the front edge of the assist step extension. 20. Install the screws to the front edge of the assist step extension. Tighten the screws to the front edge of the assist step extension to 7 N.m (62 lb in). 21. Install the assist step pad. 22. Align the assist step pad to the assist step plate and press downward firmly until fully seated. The nuts are to be hand torqued. 23. Install the assist step pad nuts. Tighten the assist step pad nuts to 2 N.m (18 lb in). 24. Lower the vehicle. Assist Step Pad Replacement Assist Step Pad Replacement Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8449 Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the assist step pad nuts. 3. Remove the assist step pad as follows: 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it is fully released from the assist step plate. Installation Procedure 1. Install the assist step pad as follows: 1. Align the assist step pad to the assist step plate and press downward firmly until seated. 2. The assist step pad nuts are to be hand torque. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step pad nuts Tighten the assist step pads nuts to 8 N.m (71 lb in). 3. Lower the vehicle. Assist Step Extension Replacement - Rear Assist Step Extension Replacement - Rear Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the front section of the assist step extension. Refer to Assist Step Plate Replacement (See: Assist Step Plate Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8450 3. Remove the screws from the left rear outer edge of the assist step extension. 4. Lift upward on the assist step extension until fully released from the retainer. 5. Remove the screws from the right rear inner and outer wheel well. 6. Open the sliding door to expose the screw. 7. Lift upward on the assist step extension until fully released from the retainer. 8. Remove the rear section of the assist step extension. Installation Procedure Important: Use the following procedure when installing the assist step extension: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8451 * Check the height and the alignment to the rocker panel. * Check the height and the alignment to the rocker panel cladding and to the body. If the vehicle is equipped with assist steps, the cladding will be shorter across the bottom. 1. Install the rear section of the assist step extension, align the rear edge of the assist step with the rear edge of the retainer and pushing downward until fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screw to the left rear outer edge of the assist step extension. Lift upward on the assist step until fully released from the retainer. Tighten the screw to the left rear outer edge of the assist step extension to 2 N.m (18 lb in). 3. Install the screws to the right rear inner and outer wheel well. Open the sliding door to expose the screw. Lift upward on the assist step extension until fully released from the retainer Tighten the screws to the right rear inner and outer wheel well to 2 N.m (18 lb in). 4. Install the front section of the assist step extension. Refer to Assist Step Plate Replacement (See: Assist Step Plate Replacement) . 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8458 Front Bumper Cover / Fascia: Service and Repair Fascia Replacement - Front Bumper Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 3. Remove the front bumper fascia to bumper lower brace bolts. 4. Remove the front bumper fascia to fender bolts. 5. Remove the front bumper fascia to impact bar push-in retainers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8459 6. Remove the front bumper fascia from the impact bar. Installation Procedure 1. Install the front bumper fascia to the impact bar. 2. Install the front bumper fascia to impact bar push-in retainers. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the front bumper fascia to the fender bolts. Tighten the bolts to 6 N.m (53 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8460 4. Install the front bumper fascia to the bumper lower brace bolts. Tighten the bolts to 6 N.m (53 lb in). 5. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 8465 Front Bumper Reinforcement: Service and Repair Impact Bar Replacement - Front Bumper Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 2. Remove the front bumper fascia. Refer to Fascia Replacement - Front Bumper (See: Front Bumper Cover / Fascia/Service and Repair) . 3. Remove the bracket bolts from the impact bar. 4. Remove the impact bar from the vehicle. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the impact bar to the bracket bolts. Tighten the bolts to 58 N.m (43 lb ft). 2. Install the front bumper fascia. Refer to Fascia Replacement - Front Bumper (See: Front Bumper Cover / Fascia/Service and Repair) . 3. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8471 Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper Removal Procedure 1. Remove the top fascia retainers. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 3. Disengage the retainers from the underside of the fascia. 4. Remove the fascia from the impact bar. Installation Procedure 1. Align the locator pin of the fascia to the hole in the impact bar. 2. Press the retainers into the underside of the fascia. 3. Lower the vehicle. 4. Install the top fascia retainers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Disconnect the windshield washer hoses from the windshield wiper arm. 2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 3. Remove the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Remove the air inlet grille panel to cowl screws. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Install the air inlet grille panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the air inlet grille panel to cowl screws. Tighten the air inlet grille panel to cowl screws 2 N.m (18 lb in). 3. Install the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair REMOVAL PROCEDURE IMPORTANT: It door lock cylinders require replacement for any reason, apply a coating of GM P/N 12346241 or equivalent lubricant inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door. 3. Remove the access hole plug (1). 4. Remove the lock rod from the door handle. 5. Remove the nuts from the door handle (4). 6. Remove the door handle from the door (2). 7. Remove the lock rod from the lock cylinder (3). 8. Remove the lock cylinder retainer. 9. Remove the lock cylinder and the gasket (5) from the door. INSTALLATION PROCEDURE IMPORTANT: Install new plastic retainer clips whenever the lock rods are removed. 1. Install the gasket (5) and the lock cylinder to the door. 2. Install the lock cylinder retainer. 3. Install the lock rod to the lock cylinder. 4. Install the handle to the door (2). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 8487 5. Install the nuts to the door handle (4). Tighten Tighten the nuts to the door handle to 6 N.m (53 lb in). 6. Install the door handle lock rod to the handle. 7. Install the access hole plug (1). 8. Install the water deflector. 9. Install the trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Hinge Replacement - Front Door Removal Procedure 1. Remove the door. Refer to Door Replacement - Front (See: Service and Repair) . 2. Remove the sealer from around the edge of the hinge. 3. Scribe the location of the existing hinges on the door and the body pillar (1). 4. Center punch each of the original welds on each hinge base (3). 5. Drill a 3.0 mm (1/8 in) pilot hole completely through each weld at each punch mark. Drill through the hinge base only. Do not drill through the door or the body pillar. 6. Drill a 13.0 mm (1/2 in) hole through the hinge base. Use the 3.0 mm (1/8 in) hole as a pilot. Do not drill through the door or the body pillar. 7. Use a chisel in order to separate any remaining weld attaching the hinge to the door or the body pillar. 8. Remove the hinge from the door or the body pillar. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Page 8491 1. Install the bolt on replacement hinge (4) to the door or the body pillar within the scribe marks (1) previously made: 1. Use the replacement hinge (4) as a template in order to center punch each bolt hole location. 2. Drill a 13.0 mm (1/2 in) hole through the door or the body pillar at the center punch marks made previously. 3. Dress and prepare the door or the hinge pillar for the replacement hinge. This includes grinding off any remaining welds. 2. Apply a medium-bodied sealer to the hinge surface that mates with the door or the hinge pillar surface. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Use the bolts and the anchor plate supplied with the replacement hinge in order to install the hinge to the door. Tighten the bolts hinge to the door to 27 N.m (20 lb ft). 4. Apply paint to the hinge and the surrounding area. 5. Install the door. 6. Adjust the door to fit properly in the door frame. The 13.0 mm (1/2 in) holes drilled for the replacement will provide for some adjustment. Do not completely shut the door until a visual check of the lock fork bolt to striker alignment is made. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement Front Door Panel: Service and Repair Panel Replacement Door Trim Panel - Front TRIM PANEL REPLACEMENT - DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the screws and the armrest cover (YC5). 2. Remove the window regulator handle, if equipped. 3. Pull out on the lock lever escutcheon, starting with the front edge, in order to remove the lock lever escutcheon. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8496 4. Pull out on the top edge of the escutcheon and pivot down in order to clear the tab at the trim panel and remove the upper corner trim if equipped. 5. Remove the caps that cover the screws retaining the assist handle. 6. Remove the screws that retain the handle to the door. 7. Remove the one screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. 10. Remove the door courtesy lamp from the door panel, if equipped. 11. Use J 38778 to release the door trim panel retainers. 12. Remove the trim panel from the door. INSTALLATION PROCEDURE IMPORTANT: Replace any trim panel retainers that were damaged during removal. 1. Position the trim panel to the door. 2. Secure the trim panel retainers to the door by pressing into the door until fully seated. 3. Place the window seal portion of the panel over the door frame in order to install the trim panel to the door. 4. Install the door courtesy lamp to the door panel. 5. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 6. Install the plate to the trim panel. 7. Install the one screw at the front edge of the accessory switch mount plate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the one screw at the front edge of the accessory switch mount plate to 2 N.m (18 lb in). 8. Install the handle to the door with screws. Tighten Tighten the handle to the door with screws to 5 N.m (44 lb in). 9. Install the caps that cover the screws on the assist handle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8497 10. Insert the tab in the slot on the door trim panel and seat the fastener into the door at the top in order to install the upper corner trim. 11. Push the lock lever escutcheon into place, starting at the rear edge. 12. Install the window regulator handle, if equipped. 13. Install the armrest cover and the screws (YC5). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8498 Tighten Tighten the armrest cover screws to 5 N.m (44 lb in). Door Trim Panel Replacement Trim Panel Replacement - Door Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the screws and the armrest cover (YC5). 2. Remove the window regulator handle, if equipped. 3. Pull out on the lock lever escutcheon, starting with the front edge, in order to remove the lock lever escutcheon. 4. Pull out on the top edge of the escutcheon and pivot down in order to clear the tab at the trim panel and remove the upper corner trim if equipped. 5. Remove the caps that cover the screws retaining the assist handle. 6. Remove the screws that retain the handle to the door. 7. Remove the one screw at the front edge of the accessory switch mount plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8499 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. 10. Remove the door courtesy lamp from the door panel, if equipped. Refer to Courtesy Lamp/Reflector Replacement - Door . 11. Use J 38778 to release the door trim panel retainers. 12. Remove the trim panel from the door. Installation Procedure Important: Replace any trim panel retainers that were damaged during removal. 1. Position the trim panel to the door. 2. Secure the trim panel retainers to the door by pressing into the door until fully seated. 3. Place the window seal portion of the panel over the door frame in order to install the trim panel to the door. 4. Install the door courtesy lamp to the door panel. Refer to Courtesy Lamp/Reflector Replacement - Door . 5. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 6. Install the plate to the trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the one screw at the front edge of the accessory switch mount plate. Tighten the one screw at the front edge of the accessory switch mount plate to 2 N.m (18 lb in). 8. Install the handle to the door with screws. Tighten the handle to the door with screws to 5 N.m (44 lb in). 9. Install the caps that cover the screws on the assist handle. 10. Insert the tab in the slot on the door trim panel and seat the fastener into the door at the top in order to install the upper corner trim. 11. Push the lock lever escutcheon into place, starting at the rear edge. 12. Install the window regulator handle, if equipped. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8500 13. Install the armrest cover and the screws (YC5). Tighten the armrest cover screws to 5 N.m (44 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8501 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: ) . 2. Use a 6 mm (0.24 in) drill bit in order to remove the head from the door bracket rivets. 3. Remove the rivets that retain the bracket to the door. Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 4. In order to remove the water deflector, several components need to be removed first. Remove the armrest bracket. 5. Remove the lock lever. 6. Use a soft-faced scraper in order to peel the water deflector away from the door. Installation Procedure Important: When replacing deflectors which have been peeled back or removed, the adhesive on the door and the deflector from the factory will usually be adequate in order to re-adhere the deflector to the door. If additional adhesive is required, use a small amount of weatherstrip adhesive, such as GM P/N 12345096, Canadian P/N 993365, or an equivalent adhesive. If the deflector was separated at a perforation, use a cloth reinforced tape with a strong adhesive in order to secure the piece together. Replace the deflector if the deflector Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8502 is too badly damaged to provide a proper seal. 1. Install the water deflector. 2. Install the lock lever. 3. Install the armrest bracket to the door. 4. Install the 6 mm (1/4 in) rivets to the door. 5. Install the trim panel. Refer to Trim Panel Replacement - Door (See: ) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement Front Door Striker: Service and Repair Door Striker Replacement Striker Replacement - Door Tools Required J 29843-9 Door Lock Striker and Seat Belt Torx Wrench Removal Procedure 1. Remove the interior trim if necessary to gain access to the striker nut. 2. Remove door striker using J 29843-9 . Hold the nut in order to prevent the nut from falling into the body pillar. 3. Remove the nut from the vehicle. 4. Remove the spacer from the vehicle. 5. Remove the insulator from the vehicle. 6. Adjust the striker to properly engage the door lock once the door is adjusted within the frame. 7. Ensure that the striker is used to adjust the door for flushness only, not to raise or lower the door. Installation Procedure 1. Install the spacer and the insulator to the striker. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the door striker using J 29843-9 . Hold the nut in order to prevent the nut from falling into the body pillar. Tighten the door striker to 67 N.m (49 lb ft). 3. Install the interior trim which was previously removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement > Page 8507 Front Door Striker: Service and Repair Striker Replacement - Sliding Door Rear Striker Replacement - Sliding Door Rear Removal Procedure 1. Remove the right hand body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . 2. Remove the two bolts that retain the rear storage compartment, if equipped. 3. Remove the bolts (5). 4. Remove the striker (4). 5. Remove the spacer (3). 6. Remove the washer (2). 7. Remove the nut plate (1). Installation Procedure 1. Install the nut plate (1). 2. Install the washer (2). 3. Install the spacer (3). 4. Install the striker (4). Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the striker bolts (5). Tighten the striker bolts to 24 N.m (18 lb ft). 6. Install the right hand body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the interior garnish moldings. 2. Use the J 38778 in order to pull the weatherstrip from the pinchweld flange of the door. Start at the upper right corner (6), and pull the weatherstrip down (5,4). Keep pulling the weatherstrip (3) until you reach the top (1) of the door, and have pulled the weatherstrip free. Installation Procedure Important: Ensure that the weatherstrip length is equally distributed around the door opening. 1. Partially attach the weatherstrip to the pinchweld flange in 6 key areas (1,2,3,4,5,6). Important: Fit the weatherstrip to the opening by hand. 2. Seat the weatherstrip onto the pinchweld flange to approximately 154 mm (6 in) on each side of the corner in order to install the weatherstrip at each corner (6,4,3,1). Important: Use a rubber mallet and hit the weatherstrip square to the flange. Otherwise, an undesirable spreading of the carrier will occur that will result in reduced retention. 3. Use a rubber mallet in order to install the weatherstrip into each corner. 4. Use a rubber mallet in order to install the pinchweld flange areas of the hinge and the windshield pillars. 5. Ensure that the following conditions are met: * The weatherstrip fits into the corner and matches the radius of the pinchweld flange. * The weatherstrip is seated completely onto the flange in all areas, resulting in a smooth vinyl-trim around the entire door opening. * There is not any distortion or excess spreading of the carrier as a result of hitting the carrier improperly with the rubber mallet. * The weatherstrip is not kinked or distorted after installation. * The weatherstrip is lubricated with GM weatherstrip silicone lube. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Page 8511 * Install the interior garnish moldings. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Upper Removal Procedure 1. Pull the molding (1) from the molding flange. 2. Remove the molding (1). Installation Procedure 1. Install the molding (1). 2. Push the molding (1) onto the flange. Start at the pre-formed corners. Work toward the straight flanges. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Motor Replacement - Power Window Removal Procedure 1. Remove the power window regulator. Refer to Window Regulator Replacement (See: Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install a self-tapping, pan head sheet metal screw through the sector gear and the backing plate at the hole provided. This will lock the sector gear into position. 3. Drill out the rivets (2) attaching the power window motor to window regulator . 4. Remove the power window motor from the window regulator (3). Installation Procedure 1. Install the power window motor to the window regulator (3). Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install the rivets (2) attaching the power window motor to window regulator . 3. Remove the self-tapping, pan head sheet metal screw through the sector gear and the backing plate hole. 4. Install the power window regulator. Refer to Window Regulator Replacement (See: Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Replacement Door Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Door Trim Panel Replacement (See: Front Door Panel/Service and Repair) . 2. Remove the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement See: Front Door Panel/Service and Repair Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward. and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure 1. Install the regulator (3) to the door: 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Front Side Door Water Deflector Replacement See: Front Door Panel/Service and Repair 5. Install the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 6. Remove the tape from the door and the window. 7. Check the window operation. 8. Install the trim panel. Refer to Door Trim Panel Replacement (See: Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 8523 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door Panel/Service and Repair) . 2. Remove the bolts that retain the inner panel upper bar. 3. Remove the water deflector. Refer to Water Deflector Replacement - Front Door See: Front Door Panel/Service and Repair. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure 1. Install the regulator (3) to the door: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 8524 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Front Door Panel/Service and Repair. 5. Install the inner panel upper bar with the bolts. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the tape from the door and the window. 7. Check the window operation. 8. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Handle Replacement - Rear Door Outside Rear Door Exterior Handle: Service and Repair Handle Replacement - Rear Door Outside Handle Replacement - Rear Door Outside Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 3. Remove the control rod from the outside handle. 4. Remove the outside handle nuts. 5. Remove the outside handle. Installation Procedure 1. Install the outside handle to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the outside handle nuts. Tighten the outside handle nuts to 7 N.m (62 lb in). 3. Install the control rod to the outside handle through the clip. 4. Install the water deflector. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 5. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Handle Replacement - Rear Door Outside > Page 8531 Rear Door Exterior Handle: Service and Repair Door Handle Replacement Outside Handle and Lock Cylinder Replacement Removal Procedure Important: If door lock cylinders require replacement for any reason, apply a coating of GM P/N 12346241 or equivalent lubricant inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door See: Front Door/Front Door Panel/Service and Repair 3. Remove the access hole plug (1). 4. Remove the lock rod from the door handle. 5. Remove the nuts from the door handle (4). 6. Remove the door handle from the door (2). 7. Remove the lock rod from the lock cylinder (3). 8. Remove the lock cylinder retainer. 9. Remove the lock cylinder and the gasket (5) from the door. Installation Procedure Important: Install new plastic retainer clips whenever the lock rods are removed. 1. Install the gasket (5) and the lock cylinder to the door. 2. Install the lock cylinder retainer . 3. Install the lock rod to the lock cylinder. 4. Install the handle to the door (2). Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the nuts to the door handle (4). Tighten the nuts to the door handle to 6 N.m (53 lb in). 6. Install the door handle lock rod to the handle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Handle Replacement - Rear Door Outside > Page 8532 7. Install the access hole plug (1). 8. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Front Door/Front Door Panel/Service and Repair 9. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door Removal Procedure 1. Remove the door from the vehicle. Refer to Door Replacement - Rear (Cargo Doors) (See: Service and Repair/Door Replacement - Rear (Cargo Doors))Door Replacement - Rear (E54) (See: Service and Repair/Door Replacement - Rear (E54)) . 2. Remove the taillamp. Refer to Tail Lamp Replacement . 3. Remove the taillamp filler panel. 4. Remove the trim panel: Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 1. Scribe an outline of the hinge halves on the door (2) and the body (1). 2. Use the template provided with the service hinge in order to center punch the existing welds. 3. Drill a 3.0 mm (1/8 in) pilot hole completely through the following components at the punch marks: * Hinge * Frame * Reinforcement * Gusset 4. Use the pilot holes as guides in order to drill a 13.0 mm (1/2 in) hole through the following components at the punch marks: * Hinge * Frame * Reinforcement * Gusset 5. Drive a chisel between the hinge and the door frame if any additional weld holds the hinge to the frame in order to remove the hinge halves. 6. Remove any additional weld on the door or the body side frame. This step may include using a grinder in order to remove any remaining weld. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Page 8536 1. Install the hinge pin bushings. 2. Apply a medium-bodied sealer to the mating surface of the hinge halves. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the following components to the door and the body frame: * Anchor plates * Bolts (3) Tighten the bolts to the door and the body frame to 27 N.m (20 lb ft). * Hinge halves Align the hinge with the previously made mark. 4. Paint the hinge and the surrounding area. 5. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 6. Install the taillamp filler panel. 7. Install the taillamp. Refer to Tail Lamp Replacement . 8. Install the door to the vehicle. Refer to Door Replacement - Rear (Cargo Doors) (See: Service and Repair/Door Replacement - Rear (Cargo Doors))Door Replacement - Rear (E54) (See: Service and Repair/Door Replacement - Rear (E54)) . 9. Adjust the door to fit properly in the door opening frame: 1. Ensure that the left door is closed when adjusting the right door. 2. Do not close the right door completely until a visual check is made in order to determine that the lock assembly is properly engaged to the striker. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) Rear Door Limiter: Service and Repair Check Link Replacement - Rear Door (Cargo Door) Check Link Replacement - Rear Door (Cargo Door) Removal Procedure 1. Open the door. 2. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 3. Remove the water deflector. 4. Remove the check link from the check link mounting bracket by lifting upward to release. Important: Remove the one screw that retains the check link lock spring, if replacing just the check link lock spring. When replacing the check link bracket all three screws will need to be removed. Remove one screw at a time when replacing the check link bracket. If all three screws are removed at once this may cause the loss of the threaded anchor plate. If this occurs, remove the taillamp and the taillamp pocket in order to access the cavity where the threaded plate is located. 5. Remove the check link screws from the bracket (2). 6. Remove the check link bracket (1) and the check link lock spring. 7. Remove the check link bolts from the door. 8. Remove the check link boot from the door (6). 9. Remove the check link (5) from the inside of the door. Installation Procedure 1. Install the check link (5) to the door. 2. Install the check link boot to the door (6). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the check link boot bolts to the door. Tighten the check link bolts to the door to 6 N.m (53 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) > Page 8541 4. Install the check link bracket (1) and the check link lock spring. 5. Install the check link bracket screws (2). Tighten the check link bracket screws to 4 N.m (35 lb in). 6. Install the water deflector. 7. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) > Page 8542 Rear Door Limiter: Service and Repair Check Link Replacement - Rear Door (E54) Check Link Replacement - Rear Door (E54) Removal Procedure 1. Open the door. 2. Remove the door trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 3. Remove the water deflector. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 4. Remove the check link from the check link mounting bracket by lifting upward to release. Important: Remove the one screw that retains the check link lock spring, if replacing just the check link lock spring. When replacing the check link bracket all three screws will need to be removed. Remove one screw at a time when replacing the check link bracket. If all three screws are removed at once this may cause the loss of the threaded anchor plate. If this occurs, remove the taillamp and the taillamp pocket in order to access the cavity where the threaded plate is located. 5. Remove the check link screws from the bracket (2). 6. Remove the check link bracket (1) and the check link lock spring. 7. Remove the check link bolts from the door. 8. Remove the check link boot from the door (6). 9. Remove the check link (5) from the inside of the door. Installation Procedure 1. Install the check link (5) to the door. 2. Install the check link boot to the door (6). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the check link boot bolts to the door. Tighten the check link bolts to the door to 6 N.m (53 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) > Page 8543 4. Install the check link bracket (1) and the check link lock spring. 5. Install the check link bracket screws (2). Tighten the check link bracket screws to 4 N.m (35 lb in). 6. Remove the water deflector. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 7. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Rear Door Trim Panel Replacement (Cargo Doors) Rear Door Trim Panel Replacement (Cargo Doors) Removal Procedure 1. Remove the window garnish molding. Refer to Window Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Window Garnish Molding Replacement). 2. Remove the screws. 3. Remove the trim panel. Installation Procedure 1. Install the trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the trim panel screws. Tighten the trim panel screws to 2 Nm (18 lb.in.). 3. Install the window garnish molding. Refer to Window Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Window Garnish Molding Replacement). Rear Door Trim Panel Replacement (E54) Rear Door Trim Panel Replacement (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8548 1. Remove the lace. 2. Use J 38778 in order to remove the trim panel. Installation Procedure 1. Install the trim panel to the door. 2. Install the lace. Door Trim Panel - Rear Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8549 TRIM PANEL REPLACEMENT - DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the screws and the armrest cover (YC5). 2. Remove the window regulator handle, if equipped. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8550 3. Pull out on the lock lever escutcheon, starting with the front edge, in order to remove the lock lever escutcheon. 4. Pull out on the top edge of the escutcheon and pivot down in order to clear the tab at the trim panel and remove the upper corner trim if equipped. 5. Remove the caps that cover the screws retaining the assist handle. 6. Remove the screws that retain the handle to the door. 7. Remove the one screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. 10. Remove the door courtesy lamp from the door panel, if equipped. 11. Use J 38778 to release the door trim panel retainers. 12. Remove the trim panel from the door. INSTALLATION PROCEDURE IMPORTANT: Replace any trim panel retainers that were damaged during removal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8551 1. Position the trim panel to the door. 2. Secure the trim panel retainers to the door by pressing into the door until fully seated. 3. Place the window seal portion of the panel over the door frame in order to install the trim panel to the door. 4. Install the door courtesy lamp to the door panel. 5. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 6. Install the plate to the trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the one screw at the front edge of the accessory switch mount plate. Tighten Tighten the one screw at the front edge of the accessory switch mount plate to 2 N.m (18 lb in). 8. Install the handle to the door with screws. Tighten Tighten the handle to the door with screws to 5 N.m (44 lb in). 9. Install the caps that cover the screws on the assist handle. 10. Insert the tab in the slot on the door trim panel and seat the fastener into the door at the top in order to install the upper corner trim. 11. Push the lock lever escutcheon into place starting at the rear edge. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8552 12. Install the window regulator handle, if equipped. 13. Install the armrest cover and the screws (YC5). Tighten Tighten the armrest cover screws to 5 N.m (44 lb in). For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8553 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 2. Peel the water deflector from the door and remove from the door. Installation Procedure 1. Install the water deflector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8554 2. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8555 Rear Door Panel: Service and Repair Access Cover Replacement - Cargo Van Upper Access Cover Replacement - Cargo Van Upper Removal Procedure 1. Remove the screws (3) that retain the upper access cover (2) to the door. 2. Remove the upper access cover (2) from the door. Installation Procedure 1. Install the upper access cover (2) to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws (3) that retain the upper access cover to the door. Tighten the screws that retain the upper access cover to the door to 4 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair Door Striker Replacement - Left Rear Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Separate the water deflector at the perforations. Use a sharp-bladed tool if needed. Refer to Water Deflector Replacement See: Rear Door Panel/Service and Repair 3. Remove the nuts from the striker (2). 4. Remove the insulator (3). 5. Remove the striker (4). Installation Procedure 1. Install the striker to the door (4). The narrow part on the wedge plate of the striker should point toward the rear of the vehicle. 2. Install the insulator (3). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the nuts to the striker (2). Tighten the nuts to the striker to 30 N.m (22 lb ft). 4. Install the water deflector. Refer to Water Deflector Replacement See: Rear Door Panel/Service and Repair 5. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Outer Belt Sealing Strip Replacement - Outer Belt Removal Procedure 1. Roll the window down. 2. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 3. Remove the outer sealing strip from the door frame. Installation Procedure 1. Install the outer sealing strip to the door frame. 2. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8563 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (Cargo Doors) Weatherstrip Replacement - Rear Door (Cargo Doors) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers (2). 2. Use the 3M Release Agent or an equivalent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic weather retainers (3). 4. Remove the weatherstrip (1) from the left door. 5. Remove the weatherstrip from the right door. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip to the right door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8564 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip (3) to the left door. 3. Install the plastic retainers (2) into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8565 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (E54) Weatherstrip Replacement - Rear Door (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers. 2. Use 3M Release Agent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic retainers. 4. Remove the left door weatherstrip. 5. Remove the right door weatherstrip. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the right door weatherstrip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8566 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the left door weatherstrip. 3. Install the plastic retainers into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Center Sliding Door Roller > Component Information > Service and Repair Center Sliding Door Roller: Service and Repair Roller Bracket Replacement - Center Removal Procedure 1. Remove the center roller track cover. Refer to Center Track Cover Replacement - Sliding Door () . 2. Position the sliding door inward for door clearance. Remove the bolts (5) that retain the center roller bracket (2) to the door. 3. Disconnect the retaining spring located around the pin in order to release. 4. Support the sliding door at the bottom rear corner. 5. Slide the bracket rearward. 6. Remove the bracket (2) from the center roller track. Installation Procedure 1. Install the bracket (2) to the center roller track. 2. Slide the bracket forward. 3. Remove the support from the sliding door. 4. Push the retaining pin back in place. 5. Check the retaining spring located around the pin for damage. If damaged, replace the spring. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the bolts (5) that retain the center roller bracket to the door. Tighten the center roller bracket retaining bolts to 35 N.m (26 lb ft). 7. Install the center roller track cover. Refer to Center Track Cover Replacement - Sliding Door () . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Roller > Component Information > Service and Repair Lower Sliding Door Roller: Service and Repair Roller Bracket Replacement - Lower Removal Procedure 1. Use a grease pencil in order to mark the position of the bracket on the door. 2. Disconnect the lower corner of the door trim panel to expose the bracket (2) to door bolts. 3. Support the bottom of the door. 4. Remove the bracket (2) to door bolts. 5. Slide the bracket (2) out of the rear of the track in order to remove the bracket from the body. Installation Procedure 1. Slide the bracket rollers (2) into the rear of the track in order to install the bracket to the body. 2. Align the bracket with the marks made during removal in order to install the bracket to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts that retain the bracket to the door. Tighten the bracket retaining bolts to 25 N.m (18 lb ft). 4. Remove the support from the bottom of the door. 5. Install the lower corner of the door trim panel by pressing into place until fully seated. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair Sliding Door Handle: Service and Repair Door Handle Replacement - Outside Sliding Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 2. Remove the water deflector. Refer to Water Deflector Replacement - Sliding Door (See: Sliding Door Interior Trim Panel/Service and Repair/Water Deflector Replacement - Sliding Door) . 3. Remove the lock control. Refer to Lock Replacement - Sliding Door (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Lock Replacement - Sliding Door) . 4. Remove the lock rods from the handle (1). 5. Remove the outside handle nuts (2). 6. Remove the outside handle and gasket from the door. Installation Procedure 1. Install the outside handle and gasket to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the outside handle nuts (2). Tighten the outside handle nuts to 6 N.m (50 lb in). 3. Install the lock rods to the handle (1). 4. Install the lock control. Refer to Lock Replacement Sliding Door (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Lock Replacement - Sliding Door) . 5. Install the water deflector. Refer to Water Deflector Replacement - Sliding Door (See: Sliding Door Interior Trim Panel/Service and Repair/Water Deflector Replacement - Sliding Door) . 6. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door Trim Panel Replacement Sliding Door Interior Trim Panel: Service and Repair Sliding Door Trim Panel Replacement Trim Panel Replacement - Sliding Door Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the screws that retain the inside handle bezel (1) to the door. 2. Pull in order to disengage the clips (2) and remove the inside handle bezel (1). 3. Remove the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. 4. Use J 38778 in order to release the trim panel retainers. 5. Remove the sliding door trim panel. Installation Procedure 1. Install the trim panel to the door: 1. Align the retainers to the holes in the door. 2. Press the panel in order to engage the retainers into the door. 2. Press in order to engage the clips (2) and install the inside handle bezel (1). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws (3) that retain the inside handle bezel (1). Tighten the screws that retain the inside handle bezel to 2 N.m (18 lb in). 4. Install the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door Trim Panel Replacement > Page 8581 Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door Trim Panel Replacement > Page 8582 Sliding Door Interior Trim Panel: Service and Repair Water Deflector Replacement - Sliding Door Water Deflector Replacement - Sliding Door Removal Procedure 1. Remove the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. 2. Remove the trim panel. Refer to Trim Panel Replacement - Sliding Door (See: ) . Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 3. Peel the water deflector (1) away from the door. Installation Procedure Important: When replacing deflectors which have been peeled back or removed, the adhesive on the door and the deflector from the factory will usually be adequate in order to re-adhere the deflector to the door. If additional adhesive is required, use a small amount of weatherstrip adhesive, such as GM P/N 12345096, Canadian P/N 993365, or an equivalent adhesive. If the deflector was separated at a perforation, use a cloth reinforced tape with a strong adhesive in order to secure the piece together. Replace the deflector if the deflector is too badly damaged to provide a proper seal. 1. Install the water deflector (1). Important: Ensure that the water deflector is properly attached to the door in order to help prevent the intrusion of exhaust gases. 2. Install the trim panel. Refer to Trim Panel Replacement - Sliding Door (See: ) . 3. Install the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Upper Sliding Door Roller > Component Information > Service and Repair Upper Sliding Door Roller: Service and Repair Roller Bracket Replacement - Upper Removal Procedure 1. Remove the upper roller bracket garnish molding. 2. Remove the rubber stopper from the upper roller track. 3. Remove the front cap. 4. Remove the bracket (1) to door bolts (4). 5. Remove the upper roller bracket from the track. Installation Procedure 1. Install the upper roller bracket (1) to the track. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bracket to door and bolts (4). Tighten the bracket bolts to the door to 25 N.m (18 lb ft). 3. Install the front cap. 4. Install the rubber stopper to the upper roller track. 5. Install the upper roller bracket garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Striker > Component Information > Service and Repair Sliding Door Striker: Service and Repair Striker Bolt Replacement - Sliding Door Front Removal Procedure 1. Remove the shoulder belt guide bolt from the door pillar. Refer to Seat Belt Retractor Replacement - Right Rear . 2. Pull the trim panel forward and reach behind the trim panel to the striker bolt nut in order to remove the screw at the bottom of the door pillar trim. 3. Remove the striker bolt (4). 4. Remove the striker nut (1). Installation Procedure 1. Install the striker nut to the inside of the door pillar. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the striker bolt (4). Tighten the striker bolt to 67 N.m (49 lb ft). 3. Install the trim panel to the door pillar and the screw. 4. Install the shoulder belt guide bolt to the door pillar. Refer to Seat Belt Retractor Replacement - Right Rear . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures Fuel Door: Procedures Fuel Filler Pocket Replacement FUEL FILLER POCKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel filler door. 2. Remove the fuel filler cap. 3. Remove the screws that retain the pocket to the fuel filler pipe. 4. Remove the screws that retain the fuel filler pocket to the body. 5. Remove the fuel filler pocket. INSTALLATION PROCEDURE 1. Install the fuel filler pocket. 2. Install the screws that retain the fuel filler pocket to the body. 3. Install the screws that retain the pocket to the fuel filler pipe. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws that retain the pocket to the fuel filler pipe to 2 N.m (18 lb in). 4. Install the fuel filler cap. 5. Install the fuel filler door. Fuel Filler Door Replacement FUEL FILLER DOOR REPLACEMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 8593 REMOVAL PROCEDURE 1. Remove the screws that retain the fuel filler door. 2. Remove the fuel filler door. INSTALLATION PROCEDURE 1. Install the fuel filler door. 2. Install the screws that retain the fuel filler door. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws that retain the fuel filler door to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 8594 Fuel Door: Removal and Replacement Fuel Filler Door Replacement Fuel Filler Door Replacement Removal Procedure 1. Remove the screws that retain the fuel filler door. 2. Remove the fuel filler door. Installation Procedure 1. Install the fuel filler door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the fuel filler door. Tighten the screws that retain the fuel filler door to 2 N.m (18 lb in). Fuel Filler Pocket Replacement Fuel Filler Pocket Replacement Removal Procedure 1. Remove the fuel filler door. Refer to Fuel Filler Door Replacement (See: Fuel Filler Door Replacement) . 2. Remove the fuel filler cap. 3. Remove the screws that retain the pocket to the fuel filler pipe. 4. Remove the screws that retain the fuel filler pocket to the body. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 8595 5. Remove the fuel filler pocket. Installation Procedure 1. Install the fuel filler pocket. 2. Install the screws that retain the fuel filler pocket to the body. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the pocket to the fuel filler pipe. Tighten the screws that retain the pocket to the fuel filler pipe to 2 N.m (18 lb in). 4. Install the fuel filler cap. 5. Install the fuel filler door. Refer to Fuel Filler Door Replacement (See: Fuel Filler Door Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure 1. Remove the air inlet panel grille. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair) . Caution: Refer to Hood Hold-Open Device Caution in Cautions and Notices. 2. Raise and support the hood. 3. Remove the hinge to fender nut. 4. Remove the hinge to fender bolt. 5. Using a grease pencil, mark the position of the hinge to hood. 6. Remove the hinge to hood bolts. 7. Remove the hinge from the hood. Installation Procedure 1. Install the hinge to the hood with the aid of an assistant. 2. Align the new hinge according to the marks made before the old hinge was removed. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the hood to hinge bolts. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 8600 Tighten the bolts to 25 N.m (18 lb ft). 4. Install the hinge to fender nut. 5. Install the hinge to fender bolt. Tighten the bolt to 25 N.m (18 lb ft). 6. Lower the hood. 7. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Raise the hood. 2. Remove the hood insulator push-in retainers by using J 38778 . 3. Remove the insulator from the hood. Installation Procedure 1. Install the hood insulator to the hood. 2. Install the hood insulator retainers into the hood by pushing in the retainers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary Hood Latch: Service and Repair Hood Latch Replacement - Primary Hood Latch Replacement - Primary Removal Procedure 1. Remove the hood release cable from the latch with the following procedure: 1. Place a screwdriver into the cable clip. 2. Pry the cable clip open in order to remove the cable. 3. Pry the cable housing from the latch. 2. Remove the primary latch support bolts to the radiator. 3. Remove the primary latch with the bracket from the vehicle. 4. Remove the bracket from the latch. Installation Procedure 1. Install the bracket to the latch. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the primary latch to the bracket bolts. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the primary latch and bracket to the vehicle. Important: In the next step, do not tighten the bolts. 4. Install the primary latch support bolts to the radiator. 5. Adjust the latch right and left until the latch lines up with the striker pins in the hood. 6. Raise the hood and tighten the latch to the radiator support bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8608 7. Use a suitable tool in order to crimp the cable clip and retain the hood release cable to the latch. 8. Verify that the hood is operating correctly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8609 Hood Latch: Service and Repair Hood Latch Replacement - Secondary Hood Latch Replacement - Secondary Removal Procedure 1. Remove the hood latch bolt. 2. Remove the secondary hood latch from the hood. Installation Procedure 1. Install the secondary hood latch to the hood. Position the tab into the slot. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the hood latch bolt Tighten the hood latch bolt to 27 N.m (20 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8610 Hood Latch: Service and Repair Hood Latch Release Handle Replacement Hood Latch Release Handle Replacement Removal Procedure 1. Remove the left cowl side trim panel. Refer to Trim Panel Replacement - Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) in Interior Trim. 2. Remove the screws that retain the hood release lever to the cowl side trim panel. 3. Remove the hood release cable from the hood latch. Refer to Hood Latch Release Cable Replacement (See: Hood Latch Release Cable/Service and Repair) . Installation Procedure 1. Install the hood release cable to the hood latch. Refer to Hood Latch Release Cable Replacement (See: Hood Latch Release Cable/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8611 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the hood release lever to the cowl side trim panel. Tighten the hood release lever screws to 8 N.m (71 lb in). 3. Install the left cowl side trim panel. Refer to Trim Panel Replacement - Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) in Interior Trim. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8612 Hood Latch: Service and Repair Hood Pop-Up Spring Replacement Hood Pop-Up Spring Replacement Removal Procedure Using a suitable flat-bladed tool, push on the hood mounted end of the spring outward to remove the spring from the hood. Installation Procedure Insert the spring into the hood retainers in order to install the spring to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure 1. Disconnect the cable from the primary latch with the following procedure: 1. Use a suitable tool to pry the cable clip open to allow removal of the cable. 2. Pry the cable housing from the latch. 2. Remove the cable from the fasteners on the radiator support. 3. Remove the cable grommet from the cowl by gently pulling on the grommet. 4. Disconnect the cable from the cowl. 5. Remove the left cowl side trim panel. Refer to Trim Panel Replacement Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) . 6. Pull the cable through the cowl in order to remove the screws that retain the cable assembly to the cowl side panel. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 8616 1. Route the cable through the front of the cowl. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the cable to cowl side panel. Tighten the screws to 2 N.m (18 lb in). 3. Install the left cowl side trim panel. Refer to Trim Panel Replacement - Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) . 4. Pull the cable assembly from the front of the cowl until the grommet is seated. 5. Connect the cable to the fasteners in the radiator support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 8617 6. Use a suitable tool in order to clamp the cable clip and connect the cable to the primary latch. 7. Verify that the hood is operating correctly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Hood Hold-Open Rod Replacement Removal Procedure Caution: Refer to Hood Hold-Open Device Caution in Cautions and Notices. 1. Raise and suitably support the hood without using the support rod. 2. Remove the support rod-to-radiator support bolt. 3. Remove the support rod from the vehicle. 4. Use a suitable tool to carefully pry the support rod retainer from the vehicle. Installation Procedure 1. Push the support rod retainer into place. 2. Insert the retainer tab into the slot in order to install the support rod to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the support rod-to-radiator support bolt. Tighten the support rod to radiator support bolts to 15 N.m (11 lb ft). 4. Lower the hood. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Measure the height of the hood adjust front bumper before removing in order to aid in adjustment. 2. Rotate the hood adjust front bumper counterclockwise. Installation Procedure 1. Rotate the hood adjust front bumpers clockwise until the hood adjust front bumper is at the same height as measured before removal. 2. Check the alignment of the hood panel assembly. Ensure the top of the hood is flush with the fenders and parallel to the grille. 3. Rotate the bumper clockwise or counterclockwise in order to align the hood. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the rear hood seal retainers by using J 38778 . 2. Remove the rear hood seal from the hood. Installation Procedure 1. Install the rear hood seal to the hood. 2. Push the retainers into the hood in order to retain the rear hood seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair Window Replacement - Lift Gate Tools Required * J 24402-A Glass Sealant (Cold Knife) Remover * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: Refer to Cracked Window Caution in Cautions and Notices. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Disconnect the washer hose from the liftgate. 2. Remove the back window wiper arm from the liftgate. Refer to Wiper Arm Replacement - Rear in Wipers/Washer Systems. 3. Open liftgate window. 4. Disconnect the electrical connector from the rear window defogger on the liftgate window. Caution: Refer to Defroster Outlet Caution in Cautions and Notices. 5. Cover to protect the following parts from broken glass: 1. Upper dash pad 2. Defroster outlets and A/C outlets 3. Seats and carpeting Important: Keep the cutting edge of the tool against the window. 6. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A , J 39032 or equivalent in order to remove the window. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 8631 7. With the aid of an assistant, remove the liftgate window from the liftgate frame. Installation Procedure 1. Install a stationary window into the opening. Refer to Urethane Adhesive Installation of Stationary Windows (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Urethane Adhesive Installation of Stationary Windows) . 2. Connect the electrical connector to the rear window defogger on the liftgate window. 3. Close liftgate window. 4. Install the back window wiper arm to the liftgate. Refer toWiper Arm Replacement - Rear in Wipers/Washer Systems. 5. Connect the washer hose to the liftgate. 6. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 8635 Liftglass Release Actuator Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 8636 Power Trunk / Liftgate Lock Actuator: Service and Repair Lock Actuator Replacement - Lift Gate Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the brace from the liftgate. 3. Remove the wiper motor from the liftgate. 4. Remove the actuator electrical connector. 5. Remove the right and the left control rods from the actuator lever. 6. Use a 5 mm (3/16 in) drill bit in order to drill out the head of the rivet. 7. Remove the actuator from the liftgate rivets. 8. Remove the actuator from the liftgate. Installation Procedure 1. Install the actuator to the liftgate. 2. Use M 39010 in order to install the actuator to the liftgate rivets. Important: Install new retainers whenever the control rods are removed. 3. Install the right and the left control rods to the actuator lever. 4. Install the wiper motor to the liftgate. 5. Install the actuator electrical connector. 6. Install the brace to the liftgate. 7. Install the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations Body Wiring - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 8640 Liftglass Lock/Unlock Release Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Latch Replacement - Lift Gate Removal Procedure 1. Remove the liftgate garnish molding (1). Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the control rods from the actuator lever (2). 3. Remove the liftgate latch screws (6). 4. Remove the slide latch (4) from the liftgate. 5. Remove the control rod from the liftgate. 6. Remove the control rod from the liftgate latch. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8645 1. Install the latch (4) with the control rod to the liftgate (3). Notice: Refer to Fastener Notice in Cautions and Notices. Important: Install the new retainers whenever the control rods are removed. 2. Install the liftgate latch screws (6). Tighten the liftgate latch screws to 10 N.m (88 lb in). 3. Use the following procedure in order to install the control rods to the actuator lever (2): 1. Push the actuator lever and the control rod together (2). 2. Push the control rod through the hole. 4. Install the liftgate garnish molding (1). Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8646 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lower Latch Replacement - Lower Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Separate the weatherstrip deflector at the perforation. Use a sharp-bladed tool if needed. Refer to Water Deflector Replacement See: Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the control rod from the lock assembly. 4. Remove the bolts and the reinforcement. 5. Remove the following components from the door: * The latch * The rod * The retainer 6. Remove the rod and the retainer from the latch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8647 Installation Procedure 1. Install the control rod and the retainer to the latch. 2. Install the retainer as shown in order to prevent squeaks and rattles. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the following components to the door. Ensure that the arrow on the retainer points toward the front of the vehicle: * The latch * The retainer * The bolts Tighten the bolts to the door to 8 N.m (71 lb in). Important: Install new nylon retainers whenever you remove the control rods. 4. Install the control rod to the lock assembly. 5. Install the water deflector. Refer to Water Deflector Replacement See: Doors/Rear Door/Rear Door Panel/Service and Repair 6. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8648 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Upper and Lower Latch Replacement - Upper and Lower Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Peel the water deflector away from the door. Use a soft-surfaced scraper if needed. Refer to Water Deflector Replacement See: Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the control rods from the remote lock. 1. Pry the anchor out of the hole. 2. Push the clip away from the lever. 3. Pull the rod and the clip away from the lever. 4. Remove the upper latch screws. 5. Remove the upper latch, if equipped. 6. Remove the upper latch and the rod from the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8649 7. Remove the lower latch screws. 8. Remove the reinforcement. 9. Remove the lower latch and the rod from the door. Installation Procedure 1. Install the clips to the remote lock. 2. Install the lower latch and the rod to the door. 3. Install the reinforcement. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8650 4. Install the lower latch screws. Tighten the lower latch screws to 8 N.m (71 lb in). 5. Install the upper latch and the rod to the door. 6. Install the cover, if equipped. 7. Install the upper latch screws. Tighten the upper latch screws to 10 N.m (88 lb in). 8. Install the control rods through the clips to the remote lock. 9. Install the water deflector. Refer to Water Deflector Replacement See: Doors/Rear Door/Rear Door Panel/Service and Repair 10. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Disconnect the electrical connector. 3. Remove the rear wiper motor from the liftgate. 4. Remove the lock cylinder retainer. 5. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the lock cylinder retainer. 3. Install the rear wiper motor to the liftgate. 4. Connect the electrical connector. 5. Install the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Locations Body Wiring - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Locations > Page 8657 Liftglass Lock/Unlock Relay Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Ball Stud Replacement - Lift Gate Trunk / Liftgate Shock / Support: Service and Repair Strut Ball Stud Replacement - Lift Gate Strut Ball Stud Replacement - Lift Gate Removal Procedure 1. Open and support the liftgate. 2. Remove the strut. Refer to Strut Replacement - Lift Gate (See: Strut Replacement - Liftgate) . 3. Remove the strut ball from the lid or body by turning counterclockwise. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the strut ball to lid or body by turning clockwise into the weldnut. Tighten the strut ball to 25 N.m (18 lb ft). 2. Install the strut. Refer to Strut Replacement - Lift Gate (See: Strut Replacement - Liftgate) . 3. Install the support. Close liftgate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Ball Stud Replacement - Lift Gate > Page 8662 Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Strut Replacement - Lift Gate Removal Procedure Caution: When a lift window hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. Notice: Apply pressure only at the end of the hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 1. Open and support the liftgate. 2. Remove the strut retaining clips from each end of the strut. Use a small flat bladed tool to lift up on the retaining clip in order to release the strut from the strut ball. 3. If equipped with a rear window defogger, remove the following components: 1. The body side rear garnish molding from the headliner Refer toTrim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) in Interior Trim. 2. The body side rear garnish molding and speaker as one Refer toTrim Replacement - Third Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Third Pillar Left) in Interior Trim. 3. The rear window defogger electrical connector from the harness 4. The grommet and electrical connector from the body, by pulling the components out 4. Remove the strut. Installation Procedure 1. Install the strut with the following steps: 1. Install the strut to each end of the strut balls. 2. Pull back on the ends of strut to ensure a firm lock. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Ball Stud Replacement - Lift Gate > Page 8663 2. If equipped with a rear defogger, install the following components: 1. The rear window defogger electrical connector to the harness 2. The grommet, fully to the body, in order to ensure that water can not enter 3. The body-side rear garnish molding and speaker as one unit Refer to Trim Replacement - Third Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Third Pillar Left) in Interior Trim. 4. The body-side rear garnish molding to the headliner Refer to Trim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) in Interior Trim. 3. Inspect the rear defogger operations. 4. Remove the prop and close the liftgate. 5. Inspect the rear defogger in order to verify that the component is operating correctly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Lift Gate Removal Procedure 1. Remove the screws (1). 2. Remove the striker assembly (2). Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. Install the liftgate striker (2) with the screws (1). Tighten the liftgate striker screws to 10 N.m (88 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the door. 2. Remove the fourth pillar trim. Refer to Trim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) and Trim Replacement - Fourth Pillar Right (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Right) in Interior Trim. 3. Remove the rear upper garnish molding. Refer to Garnish Molding Replacement - Rear Upper (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) in Interior Trim. 4. Remove the body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) and Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) in Interior Trim. 5. Remove the rear trim plate. Refer to Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Carpet Retainer Replacement) in Interior Trim. 6. Pull the weatherstrip from the pinch-weld flange. Start at the upper right corner. Installation Procedure Important: The weatherstrip attaches to the pinch-weld flange in 6 areas. The weatherstrip length distributes equally around the door opening. 1. Install the weatherstrip at the top right corner. Seat the weatherstrip onto the pinch-weld flange. 2. Position and install the weatherstrip by hand. 3. Using a rubber mallet during the final installation may be required in the thick flange areas and in each corner. 4. Install the rear trim plate. Refer to Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Carpet Retainer Replacement) in Interior Trim. 5. Install the body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) and Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) in Interior Trim. 6. Install the rear upper garnish molding. Refer to Garnish Molding Replacement - Rear Upper (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) in Interior Trim. 7. Install the fourth pillar trim. Refer to Trim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) and Trim Replacement - Fourth Pillar Right (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Right) in Interior Trim. 8. Close the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Molding/Nameplate Replacement - Exterior Trim Body Emblem: Service and Repair Molding/Nameplate Replacement - Exterior Trim Molding/Nameplate Replacement - Exterior Trim Tools Required J 41409 Body Molding Removal Tool Removal Procedure Remove the emblem or the molding: 1. Apply masking tape to the body side border of the emblem or the molding in order to protect the body from scratches. The tape will also aid in aligning the moldings during installation. 2. Use J 41409 or a 0.8 mm (0.03 in) fishing line in order to cut through the adhesive material. Installation Procedure Important: Apply these items in an environment free of dust or dirt that could come in contact with the sticky backing and prevent proper adhesion. 1. Clean the area where the molding or the emblem is to be mounted. Use a suitable solvent, such as a mixture of 50 percent isopropyl alcohol and 50 percent water, or equivalent. 2. Dry the area thoroughly. 3. Ensure that the body area is at a temperature range of 27-41°C (80-105°F). Heat the area, if needed. 4. Ensure that the emblems are at a temperature range of 29-32°C (85-90°F). Place the emblem, adhesive side down, on a heated surface or use a heat lamp or a heat gun in order to raise the temperature. 5. Remove the protective liner on the back of the molding or the emblem. 6. Apply the molding or the emblem to the body surface. 7. Apply an equal amount of pressure along the molding or the emblem in order to uniformly bond the molding or the emblem to the body surface. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Molding/Nameplate Replacement - Exterior Trim > Page 8677 Body Emblem: Service and Repair Door Lower Molding Replacement (Rear Door) Emblem Replacement - Grille Removal Procedure 1. Remove the grille from the vehicle. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) . 2. Protect the face of the grille while removing the grille emblem. 3. Remove the nuts from the back side of the grille emblem. 4. Remove the grille emblem from the grille. Installation Procedure 1. Install the grille emblem to the grille. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts to the back side of the grille emblem. Tighten the emblem nuts to the grille to 2.5 N.m (22 lb in). 3. Install the grille to the vehicle. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Disconnect the windshield washer hoses from the windshield wiper arm. 2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 3. Remove the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Remove the air inlet grille panel to cowl screws. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Install the air inlet grille panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the air inlet grille panel to cowl screws. Tighten the air inlet grille panel to cowl screws 2 N.m (18 lb in). 3. Install the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Service and Repair License Plate Bracket: Service and Repair License Plate Pocket Replacement Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. Refer to Water Deflector Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the lamp harness from the license plate housing (2). 4. Remove the bolts (1) from the housing. 5. Remove the door handle. Refer to Handle Replacement - Rear Door Outside (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Exterior Handle/Service and Repair/Handle Replacement - Rear Door Outside) . 6. Remove the housing from the door (2). Installation Procedure 1. Install the housing (2) to the door. 2. Install the door handle. Refer to Handle Replacement Rear Door Outside (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Exterior Handle/Service and Repair/Handle Replacement - Rear Door Outside) . Notice: Refer toFastener Notice Fastener Notice in Cautions and Notices. 3. Install the housing to door bolts (1). Tighten the door bolts to 4 N.m (35 lb in). 4. Install the lamp harness to the housing. 5. Install the water deflector. Refer to Water Deflector Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 6. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side Upper Side Moulding / Trim: Service and Repair Blackout Transfer Replacement - Body Side Blackout Transfer Replacement - Body Side Removal Procedure The body side blackout transfers will require removal of all windows in the area of the transfer. The forward transfers will require the removal of the front body side windows. The rearward transfers will require the removal of the front and the rear body side windows. 1. Remove the interior trim, as needed, in order to ease window removal. 2. Remove the swing-out and/or stationary window(s). Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 3. Remove the body side swing-out window weather-strip, if equipped. Refer to Weatherstrip Replacement - Swing Out Window (See: Weatherstrip/Quarter Window Glass Weatherstrip/Service and Repair) in Stationary Windows. Important: Apply all transfers in a clean environment where dust or fibers will not interfere with proper adhesion. 4. Use a heat gun or other suitable tool in order to heat the transfer and slowly peel the transfer from the body. Installation Procedure 1. Clean the area where the transfer will be mounted. Use a suitable solvent such as a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. Important: If paint in the area is chipped or gouged, repaint the area. Otherwise, the surface imperfection will be visible through the blackout transfer. 3. Position the transfer to the body. 4. Use a wax pencil in order to mark the upper and the lower locations of the transfer on the body. 5. Starting at the top of the transfer, peel the backing paper from a workable section of the transfer and begin applying the transfer to the body. Continue the application in small, workable sections until finished. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8688 Important: Use care in order not to stretch the transfer during application. 6. Use a small roller or other suitable tool in order to gently press the transfer to the body in order to ensure proper adhesion. 7. Verify that there are no air bubbles visible on the transfer. If there are air bubbles, use a small pin in order to help eliminate the air bubbles. 8. Install the body side swing-out window weather-strip, if equipped. Refer to Weatherstrip Replacement - Swing Out Window (See: Weatherstrip/Quarter Window Glass Weatherstrip/Service and Repair) in Stationary Windows. 9. Install the swing-out and/or stationary window(s). Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows: 10. Install the interior trim, as needed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8689 Upper Side Moulding / Trim: Service and Repair Blackout Transfer Replacement - Front Door Blackout Transfer Replacement - Front Door Removal Procedure 1. Remove the door trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Remove the door window run channel from the door frame. 3. Remove the emblem from the door. Refer to Molding/Nameplate Replacement - Exterior Trim (See: Body Emblem/Service and Repair/Molding/Nameplate Replacement - Exterior Trim) . Important: Apply the transfers in a clean environment where dust or fibers will not interfere with proper adhesion. 4. Use a heat gun or other suitable tool in order to heat the transfer. 5. Slowly peel the transfer from the door. Installation Procedure 1. Clean the area where the transfer will be mounted. Use a suitable solvent, such as a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. Important: If paint in the area is chipped or gouged, repaint the area, otherwise the surface imperfection will be visible through the blackout transfer. 3. Position the transfer to the door. 4. Use a wax pencil in order to mark the upper and the lower locations of the transfer on the door. 5. Begin at the top of the transfer and peel the backing paper from a workable section of the transfer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8690 6. Begin applying the transfer to the door. Continue applying the transfer to the door in small, workable sections, until finished. Important: Use care not to stretch the transfer during application. 7. Use a small roller or other suitable tool in order to gently press the transfer to the door and insure proper adhesion. 8. Verify that there are no air bubbles visible on the transfer. If there are air bubbles, use a small pin in order to help eliminate the air bubbles. 9. Install the emblem to the door. Refer to Molding/Nameplate Replacement - Exterior Trim (See: Body Emblem/Service and Repair/Molding/Nameplate Replacement - Exterior Trim) . 10. Install the door window run channel to the door frame. 11. Install the door trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8691 Upper Side Moulding / Trim: Service and Repair Cladding Replacement - Adhesive Retained Cladding Replacement - Adhesive Retained Tools Required * J 41409 Body Molding Removal Tool * 3M 07502 3M Scotch Brite Adhesive Stripe and Removal Disc, or equivalent Attach body cladding to the body with a varying combination of the following items: * Double-sided adhesive tape (1) * Plastic retainers (4) * Screws (2) In order to ensure a good replacement of new or old adhesive retained cladding, ensure that the panel surface temperature is approximately 24-41°C (80-105°F), and the panel surface is clean and free of any wax or oily film. If you will be painting the cladding, do not bake the cladding. Doing this will distort the part, making it useless. Ensure that the replacement screws on the rear side door have a head no taller than the original screws. If screws with a taller head are used, they can cause damage to the body due to physical interference when the door is opened. General procedures are listed below in order to remove adhesive retained to the cladding, and in order to replace the adhesive retained to the cladding. Refer to Cladding Replacement specific component replacement procedures. Removal Procedure 1. Apply masking tape to the body side border of the cladding in order to protect the body from scratches. The tape will also aid in aligning the cladding during installation. 2. Remove all of the mechanical fasteners. Refer to the Cladding Replacement procedure below that is specific to the cladding location. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8692 3. Use the J 41409 or a 0.8 mm (0.03 in) fishing line in order to cut through the adhesive material. Installation Procedure 1. Use a general purpose adhesive remover or an adhesive removal disc (3M 07502 or equivalent) attached to a drill in order to remove all traces of adhesive from the body panel. A 2-3 inch square rubber or felt block may also be used in order to aid in the removal of old adhesive. 2. Clean the affected panel area with wax and grease remover, and wipe with isopropyl alcohol. 3. Mark the proper position of the cladding with masking tape. Use the adjacent cladding as a guide. 4. Warm the body panel with a heat gun or a heat lamp to 24-41°C (80-105°F). 5. Make a trial fitting of the piece to the vehicle, checking the alignment and all the gaps and the clearances. Do this before you remove the plastic backing. Important: Do not distort the part while you are installing the part. The part may take a temporary set to the distorted shape and appear to have the proper adhesion, but the part will spring back to its original shape and cause a loss of adhesion. 6. Once you are satisfied with the trial fit, peel the backing from all of the tape. Set the top row of tape first, and work down the panel to the other rows of tape. Important: Once the cladding is set into place, do not attempt to remove the panel. This will destroy the adhesive strips and could lead to part distortion and damage. 7. Hand roll the cladding to the body in order to ensure proper adhesion. A shop towel rolled into a ball and held in the palm of your fist will aid in applying a consistent, evenly distributed pressure to the panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8693 Upper Side Moulding / Trim: Service and Repair Cladding Replacement - Left Quarter Panel Cladding Replacement - Left Quarter Panel Removal Procedure 1. Remove the wheel opening screws. If the vehicle is equipped with assist steps, the cladding will be shorter across the bottom. 2. Remove the cladding from the rear quarter panel. Refer toCladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Installation Procedure 1. Install the cladding to the rear quarter panel. Refer to Cladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the wheel opening screws. Tighten the wheel opening screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8694 Upper Side Moulding / Trim: Service and Repair Blackout Transfer Replacement - Body Side Blackout Transfer Replacement - Body Side Removal Procedure The body side blackout transfers will require removal of all windows in the area of the transfer. The forward transfers will require the removal of the front body side windows. The rearward transfers will require the removal of the front and the rear body side windows. 1. Remove the interior trim, as needed, in order to ease window removal. 2. Remove the swing-out and/or stationary window(s). Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 3. Remove the body side swing-out window weather-strip, if equipped. Refer to Weatherstrip Replacement - Swing Out Window (See: Weatherstrip/Quarter Window Glass Weatherstrip/Service and Repair) in Stationary Windows. Important: Apply all transfers in a clean environment where dust or fibers will not interfere with proper adhesion. 4. Use a heat gun or other suitable tool in order to heat the transfer and slowly peel the transfer from the body. Installation Procedure 1. Clean the area where the transfer will be mounted. Use a suitable solvent such as a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. Important: If paint in the area is chipped or gouged, repaint the area. Otherwise, the surface imperfection will be visible through the blackout transfer. 3. Position the transfer to the body. 4. Use a wax pencil in order to mark the upper and the lower locations of the transfer on the body. 5. Starting at the top of the transfer, peel the backing paper from a workable section of the transfer and begin applying the transfer to the body. Continue the application in small, workable sections until finished. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8695 Important: Use care in order not to stretch the transfer during application. 6. Use a small roller or other suitable tool in order to gently press the transfer to the body in order to ensure proper adhesion. 7. Verify that there are no air bubbles visible on the transfer. If there are air bubbles, use a small pin in order to help eliminate the air bubbles. 8. Install the body side swing-out window weather-strip, if equipped. Refer to Weatherstrip Replacement - Swing Out Window (See: Weatherstrip/Quarter Window Glass Weatherstrip/Service and Repair) in Stationary Windows. 9. Install the swing-out and/or stationary window(s). Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows: 10. Install the interior trim, as needed. Blackout Transfer Replacement - Front Door Blackout Transfer Replacement - Front Door Removal Procedure 1. Remove the door trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Remove the door window run channel from the door frame. 3. Remove the emblem from the door. Refer to Molding/Nameplate Replacement - Exterior Trim (See: Body Emblem/Service and Repair/Molding/Nameplate Replacement - Exterior Trim) . Important: Apply the transfers in a clean environment where dust or fibers will not interfere with proper adhesion. 4. Use a heat gun or other suitable tool in order to heat the transfer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8696 5. Slowly peel the transfer from the door. Installation Procedure 1. Clean the area where the transfer will be mounted. Use a suitable solvent, such as a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. Important: If paint in the area is chipped or gouged, repaint the area, otherwise the surface imperfection will be visible through the blackout transfer. 3. Position the transfer to the door. 4. Use a wax pencil in order to mark the upper and the lower locations of the transfer on the door. 5. Begin at the top of the transfer and peel the backing paper from a workable section of the transfer. 6. Begin applying the transfer to the door. Continue applying the transfer to the door in small, workable sections, until finished. Important: Use care not to stretch the transfer during application. 7. Use a small roller or other suitable tool in order to gently press the transfer to the door and insure proper adhesion. 8. Verify that there are no air bubbles visible on the transfer. If there are air bubbles, use a small pin in order to help eliminate the air bubbles. 9. Install the emblem to the door. Refer to Molding/Nameplate Replacement - Exterior Trim (See: Body Emblem/Service and Repair/Molding/Nameplate Replacement - Exterior Trim) . 10. Install the door window run channel to the door frame. 11. Install the door trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8697 and Repair) . Cladding Replacement - Adhesive Retained Cladding Replacement - Adhesive Retained Tools Required * J 41409 Body Molding Removal Tool * 3M 07502 3M Scotch Brite Adhesive Stripe and Removal Disc, or equivalent Attach body cladding to the body with a varying combination of the following items: * Double-sided adhesive tape (1) * Plastic retainers (4) * Screws (2) In order to ensure a good replacement of new or old adhesive retained cladding, ensure that the panel surface temperature is approximately 24-41°C (80-105°F), and the panel surface is clean and free of any wax or oily film. If you will be painting the cladding, do not bake the cladding. Doing this will distort the part, making it useless. Ensure that the replacement screws on the rear side door have a head no taller than the original screws. If screws with a taller head are used, they can cause damage to the body due to physical interference when the door is opened. General procedures are listed below in order to remove adhesive retained to the cladding, and in order to replace the adhesive retained to the cladding. Refer to Cladding Replacement specific component replacement procedures. Removal Procedure 1. Apply masking tape to the body side border of the cladding in order to protect the body from scratches. The tape will also aid in aligning the cladding during installation. 2. Remove all of the mechanical fasteners. Refer to the Cladding Replacement procedure below that is specific to the cladding location. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8698 3. Use the J 41409 or a 0.8 mm (0.03 in) fishing line in order to cut through the adhesive material. Installation Procedure 1. Use a general purpose adhesive remover or an adhesive removal disc (3M 07502 or equivalent) attached to a drill in order to remove all traces of adhesive from the body panel. A 2-3 inch square rubber or felt block may also be used in order to aid in the removal of old adhesive. 2. Clean the affected panel area with wax and grease remover, and wipe with isopropyl alcohol. 3. Mark the proper position of the cladding with masking tape. Use the adjacent cladding as a guide. 4. Warm the body panel with a heat gun or a heat lamp to 24-41°C (80-105°F). 5. Make a trial fitting of the piece to the vehicle, checking the alignment and all the gaps and the clearances. Do this before you remove the plastic backing. Important: Do not distort the part while you are installing the part. The part may take a temporary set to the distorted shape and appear to have the proper adhesion, but the part will spring back to its original shape and cause a loss of adhesion. 6. Once you are satisfied with the trial fit, peel the backing from all of the tape. Set the top row of tape first, and work down the panel to the other rows of tape. Important: Once the cladding is set into place, do not attempt to remove the panel. This will destroy the adhesive strips and could lead to part distortion and damage. 7. Hand roll the cladding to the body in order to ensure proper adhesion. A shop towel rolled into a ball and held in the palm of your fist will aid in applying a consistent, evenly distributed pressure to the panel. Cladding Replacement - Left Quarter Panel Cladding Replacement - Left Quarter Panel Removal Procedure 1. Remove the wheel opening screws. If the vehicle is equipped with assist steps, the cladding will be shorter across the bottom. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8699 2. Remove the cladding from the rear quarter panel. Refer toCladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Installation Procedure 1. Install the cladding to the rear quarter panel. Refer to Cladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the wheel opening screws. Tighten the wheel opening screws to 2 N.m (18 lb in). Cladding Replacement - Right Quarter Panel Cladding Replacement - Right Quarter Panel Removal Procedure 1. Remove the rear corner extension molding retainers. 2. Remove the rear corner extension molding. 3. Remove the cladding screws. 4. Remove the cladding retainers. 5. Remove the cladding from the body. Refer to Cladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8700 Installation Procedure 1. Install the cladding to the body. Refer to Cladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the cladding screws. Tighten the cladding screws to 2 N.m (18 lb in). 3. Install the cladding retainers. 4. Install the rear corner extension molding. 5. Install the rear corner extension molding retainers. Cladding Replacement - Left Rocker Panel Cladding Replacement - Left Rocker Panel Removal Procedure 1. Remove the screws from the cladding. 2. Remove the retainers from the wheelhouse. 3. Remove the nut on the back of the cladding from the stud. 4. Remove the cladding from the retaining rail. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8701 5. Remove the retaining rail screws. 6. Remove the retaining rail from the body. Installation Procedure 1. Install the retaining rail to the body. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the retaining rail screws. Tighten the retaining rail screws to 2 N.m (18 lb in). 3. Install the cladding to the vehicle. 4. Install the nut on the back of the cladding to the stud. Tighten the nut to 7 N.m (62 lb in). 5. Install the screws into the cladding. Tighten the screws to 2 N.m (18 lb in). 6. Install the retainers into the wheelhouse extension flange. Cladding Replacement - Right Rocker Panel Cladding Replacement - Right Rocker Panel Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8702 Removal Procedure 1. Remove the screws retaining the front half of the cladding to the front wheelhouse. 2. Remove the push-in retainers from the front wheelhouse. 3. Remove the nut from the stud on the front half of the cladding. 4. Remove the push-in retainers that retain the front half of the cladding to the retaining rail. 5. Remove the cladding from the retaining rail. 6. Remove the screws retaining the rear half of the cladding to the rear wheelhouse. 7. Remove the push-in retainers that retain the rear half of the cladding to the retaining rail. 8. Remove the retaining rail screws. 9. Remove the retaining rail from the body. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Blackout Transfer Replacement - Body Side > Page 8703 1. Install the retaining rail to the body. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the retaining rail screws. Tighten the retaining rail screws to 2 N.m (18 lb in). 3. Install the rear half of the cladding to the retaining rail. 4. Install the push-in retainers that retain the cladding to the retaining rail. 5. Install the screws that retain the cladding to the rear wheelhouse. Tighten the screws to 2 N.m (18 lb in). 6. Install the front half of the cladding to the retaining rail. 7. Install the push-in retainers that retain the front half of the cladding to the retaining rail. 8. Install the nut on the back of the cladding to the stud. Tighten the nut to 7 N.m (62 lb in). 9. Install the retainers into the front wheelhouse extension flange. 10. Install the screws retaining the front half of the cladding to the front wheelhouse. Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Splash Shield Replacement - Wheelhouse Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use J 38778 to remove the retainers from the wheelhouse and the splash shield. 2. Remove the wheelhouse splash shield from the wheelhouse. Installation Procedure 1. Install the wheelhouse splash shield to the wheelhouse. 2. Push the retainers into the wheelhouse holes in order to retain the splash shield to the wheelhouse. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair Wheelhouse Extension Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use J 38778 in order to remove the retainers from the fender and the extension and from the wheelhouse. 2. Remove the extension from the wheelhouse. Installation Procedure 1. Install the extension to the wheelhouse. 2. Install the extension push pins to the wheelhouse. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement Tools Required J 41602 Body Protection Hoist Adapter Set Removal Procedure 1. Raise the vehicle at the frame. Refer to Lifting and Jacking the Vehicle in General Information. Important: Properly support the frame and the body while changing the mount. If you are changing only one mount, the entire side on which the mount is placed must be lowered enough to provide clearance for the mount. 2. Use the J 41602 in order to support the body at the pinchweld flange. 3. Remove the bolts that retain the front bumper fascia at the brace. 4. Remove the bolts that retain the front bumper fascia at the fender. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Page 8717 5. Remove the bolt, the retainer, and the lower insulator of the mount: 1. Loosen the remaining bolts on that side far enough for the upper insulator to be removed. 2. Gradually lower the screw jack in order to allow the frame to come away from the body. 6. Remove the upper body insulator. Installation Procedure 1. Install the upper body insulator: 1. Gradually raise the screw jack in order to allow the frame to meet the body. 2. Tighten the bolts of the mounts not replaced. Do not torque at this time. 2. Install the lower insulator, the retainer, and the bolt to the mount. Do not tighten. Important: Follow the body mount tightening sequence. 3. Snug the right #2 body mount (2). 4. Snug the left #2 body mount (2). Notice: Refer to Fastener Notice in Cautions and Notices. 5. Tighten the remaining body mounts: * Tighten the center mount bolt to 155 N.m (114 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Page 8718 * Tighten the end mount bolts to 90 N.m (66 lb ft). 6. Reinstall the bumper fascia bolts. Tighten the bumper fascia bolts to 6 N.m (53 lb in). 7. Remove the screw jack. 8. Lower the vehicle. 9. Remove the J 41602 from the pinchweld flange. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody Cross-Member: Service and Repair Frame and Underbody Crossmember Brace Replacement - Front Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the bolts that retain the forward edge of the crossmember brace to the frame. 3. Remove the bolts and the nuts that retain the rear edge of the crossmember brace to the frame. 4. Remove the crossmember brace from the frame. Installation Procedure 1. Install the crossmember brace to the frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts and the nuts in order to retain the rear edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts and the nuts to 35 N.m (26 lb ft). 3. Install the bolts that retain the forward edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts to 35 N.m (26 lb ft). 4. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 8723 Cross-Member: Service and Repair Frame Stop Replacement Frame Stop Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the bolts that retain the frame stop to the frame. 3. Remove the frame stop. Installation Procedure 1. Install the frame stop. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the frame stop to the frame. Tighten the bolts that retain the frame stop to 35 N.m (26 lb ft). 3. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 8724 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Support the transmission with a transmission jack. 3. Remove the two nuts securing the transmission mount to the transmission support. 4. Remove the transmission support nuts and bolts. 5. Remove the transmission support from the vehicle. Installation Procedure 1. Install the transmission support to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the transmission support nuts and bolts. Tighten the nuts and bolts to 70 N.m (52 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 8725 3. Install the two nuts securing the transmission mount to the transmission support. Tighten the nuts to 45 N.m (33 lb ft). 4. Remove the transmission jack. 5. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the hitch from the frame nuts. 3. Remove the hitch to frame bolts. 4. Remove the hitch and bumper from the vehicle. 5. Remove the hitch to bumper nuts. 6. Remove the hitch to bumper bolts. 7. Remove the hitch from the bumper. Installation Procedure 1. Install the hitch to the bumper. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the hitch to bumper bolts. Tighten the hitch to bumper bolts to 35 N.m (26 lb ft). 3. Install the hitch to bumper nuts. Tighten the hitch to bumper nuts to 25 N.m (18 lb ft). 4. Install the hitch and the bumper to the vehicle. 5. Install the hitch to frame nuts. Tighten the hitch to frame nuts to 60 N.m (44 lb ft). 6. Install the hitch to frame bolts. Tighten the hitch to frame bolts to 55 N.m (41 lb ft). 7. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Molding Replacement - Lower Grille: Service and Repair Grille Molding Replacement - Lower Grille Molding Replacement - Lower Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille Replacement) . 2. Remove the push-in fasteners that retain the grille molding. 3. Remove the grille molding from the vehicle. Installation Procedure 1. Install the grille molding to the vehicle. 2. Install the push-in fasteners that retain the grille molding. 3. Install the grille. Refer to Grille Replacement (See: Grille Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Molding Replacement - Lower > Page 8733 Grille: Service and Repair Grille Replacement Grille Replacement Removal Procedure 1. Remove the park/turn signal lamp. Refer to Park/Turn Signal Lamp Replacement . 2. Remove the screws from the grille to radiator support. 3. Remove the screw from the signal housing. 4. Remove the grille from the vehicle. Installation Procedure 1. Install the grille to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws to grille to radiator support. Tighten the screws to the grille to radiator support to 3 N.m (27 lb in). 3. Install the park/turn signal lamp. Refer to Park/Turn Signal Lamp Replacement in Lighting Systems. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) Arm Rest: Service and Repair Armrest Replacement (YC6) Armrest Replacement (YC6) Removal Procedure 1. Remove the armrest by rotating it to the down position. Slip a pair of snap-ring pliers between the seat and the armrest. 2. Ensure that the snap-ring pliers go between the arms of the snap plate. 3. Keeping the armrest plate arms open, pull the armrest straight back off the seat post. Installation Procedure 1. Install the armrest by setting it at approximately 45 degrees. 2. Press the armrest until fully engaged into the groove of the seat post (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8739 Arm Rest: Service and Repair Armrest Replacement (YC7) Armrest Replacement (YC7) Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . 2. Place the seat in the fully upright position. 3. Release the J-hook at the bottom of the seat back. 4. Reach up and inside the seat back. Remove the armrest retaining clip. 5. Slide the armrest assembly out of the seat back. 6. Remove the armrest cover for cleaning or replacement: 1. Unzip the armrest cover. 2. Pull the armrest cover off of the seat pad. Installation Procedure 1. Install the armrest cover to the armrest, if the cover was removed. 2. Reach inside the seat back and insert the armrest retaining clip into the seat back frame. * Install the retaining clip with the opening facing down. * Observe the fit of the clip once installed. If the clip is loose when fitted in the groove in the seat back frame, remove the clip and crimp the clip closed slightly. Repeat this procedure until the clip fits snugly in the groove, or install a new clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8740 3. Insert the armrest into the seat back until the armrest retaining clip engages the groove on the armrest post. Pull on the armrest in order to verify that the clip is holding. 4. Attach the halves of the J-hook along the bottom edge of the seat back. 5. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8741 Arm Rest: Service and Repair Armrest Replacement - Rear Seat (YC7) Armrest Replacement - Rear Seat (YC7) Removal Procedure 1. Place the seat back in the fully-upright position. 2. Release the J-hook along the bottom edge of the seat back. 3. Reach up inside the seat back. Remove the armrest retaining clip. 4. Slide the armrest assembly out of the seat back. 5. Remove the armrest cover for cleaning or replacement, if needed: 1. Unzip the cover. 2. Slide the cover off the armrest. Installation Procedure 1. Install the armrest cover to the armrest, if you removed the cover. 2. Reach inside the seat back. Install the armrest retaining clip: * Install the clip with the opening facing down. * Check the fit of the clip once installed. If the clip is loose when fitted in the groove in the seat back frame, remove the clip and crimp the clip closed slightly. Repeat this procedure until the clip fits snugly in the groove, or install a new clip. 3. Insert the armrest into the seat back until the clip engages the groove on the armrest post. 4. Pull on the armrest in order to verify that the clip is holding the armrest securely. 5. Attach the halves of the J-hook along the bottom edge of the seat back. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8742 Arm Rest: Service and Repair Armrest Replacement - Rear Seat (YC5 and YC6) Armrest Replacement - Rear Seat (YC5 and YC6) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer toSeat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) . 2. Fold down the seat back. 3. Remove the upper and lower seat back latch and seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Left (See: Seats/Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Left) , or Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seats/Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Right (YC6)) . 4. Unzip the seat back cover. 5. Reach inside the seat back and remove the armrest retaining clip from the stud. 6. Remove the armrest from the seat back. 7. Remove the armrest cover for cleaning or replacement, if needed: 1. Unzip the cover. 2. Slide the cover off the armrest. Installation Procedure 1. Install the armrest cover to the armrest, if you removed the cover. 2. Install the armrest from the seat back. 3. Reach inside the seat back and install the armrest retaining clip. * Install the clip with the opening facing down. * Observe the fit of the clip once installed. If the clip is loose when fitted in the groove in the seat back frame, remove the clip and crimp the clip closed slightly. Repeat this procedure until the clip fits snugly in the groove, or install a new clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8743 4. Zip the seat back cover. 5. Install the upper and lower seat back latch and seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Left (See: Seats/Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Left) , or Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seats/Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Right (YC6)) . 6. Fold up the seat back. 7. Install the rear bench seat to the Vehicle. Refer toSeat Replacement Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8748 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8749 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8750 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8751 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement Carpet: Service and Repair Carpet Retainer Replacement Carpet Retainer Replacement Removal Procedure 1. Open the door(s). 2. Remove the screws that retain the left front door step trim plate to the vehicle. 3. Remove the screws that retain the right front door step trim plate to the vehicle. 4. Remove the screws that retain the sliding door step trim plate to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8754 5. Remove the screws that retain the rear trim plate to the vehicle. 6. Remove the trim plate from the vehicle. Installation Procedure 1. Install the trim plate to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the left front door step trim plate to the vehicle. Tighten the screws that retain the left front door step trim plate to 2 N.m (18 lb in). 3. Install the screws that retain the right front door step trim plate. Tighten the screws that retain the right front door step trim plate to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8755 4. Install the screws that retain the sliding door step trim plate to the vehicle. Tighten the screws that retain the sliding door step trim plate to 2 N.m (18 lb in). 5. Install the screws that retain the rear trim plate to the vehicle. Tighten the screws that retain the rear trim plate to 2 N.m (18 lb in). 6. Close the door(s). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8756 Carpet: Service and Repair Mat Replacement - Stepwell Mat Replacement - Stepwell Removal Procedure 1. Remove the screws from the step plate cover. 2. Remove the step panel cover. Installation Procedure 1. Install the step panel cover. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the step panel cover screws. Tighten the step panel cover screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8757 Carpet: Service and Repair Mat/Carpet Replacement - Front Floor Mat/Carpet Replacement - Front Floor Removal Procedure 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . 2. Remove the engine cover, if required. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 9. Remove the carpet/mat from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. Tighten the screws to 2 N.m (18 lb in). 4. Install the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8758 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 7. Install the engine cover, if required. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 8. Install the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) in Seats. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8759 Carpet: Service and Repair Mat/Carpet Replacement - Rear Floor Mat/Carpet Replacement - Rear Floor Removal Procedure 1. Unsnap the seat belts from the second seat belt latches. 2. Remove the seats from the vehicle. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement Rear Bench) in Seats. 3. Remove the front and the rear door trim plates. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 4. Remove the body side front lower trim panel, if required. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 5. Remove the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. Important: The carpet bezels are retained by sonic weld and are not to be removed from the carpet. 6. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet into the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. Tighten the bolt to 2 N.m (18 lb in). 3. Install the body side front lower trim panel, if removed. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 4. Install the front and the rear door trim plates. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 5. Install the seats to the vehicle. Refer to Seat Replacement Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 6. Snap the seat belts to the second seat belt latches. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8760 Carpet: Service and Repair Carpet Retainer Replacement Carpet Retainer Replacement Removal Procedure 1. Open the door(s). 2. Remove the screws that retain the left front door step trim plate to the vehicle. 3. Remove the screws that retain the right front door step trim plate to the vehicle. 4. Remove the screws that retain the sliding door step trim plate to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8761 5. Remove the screws that retain the rear trim plate to the vehicle. 6. Remove the trim plate from the vehicle. Installation Procedure 1. Install the trim plate to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the left front door step trim plate to the vehicle. Tighten the screws that retain the left front door step trim plate to 2 N.m (18 lb in). 3. Install the screws that retain the right front door step trim plate. Tighten the screws that retain the right front door step trim plate to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8762 4. Install the screws that retain the sliding door step trim plate to the vehicle. Tighten the screws that retain the sliding door step trim plate to 2 N.m (18 lb in). 5. Install the screws that retain the rear trim plate to the vehicle. Tighten the screws that retain the rear trim plate to 2 N.m (18 lb in). 6. Close the door(s). Mat Replacement - Stepwell Mat Replacement - Stepwell Removal Procedure 1. Remove the screws from the step plate cover. 2. Remove the step panel cover. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8763 1. Install the step panel cover. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the step panel cover screws. Tighten the step panel cover screws to 2 N.m (18 lb in). Mat/Carpet Replacement - Front Floor Mat/Carpet Replacement - Front Floor Removal Procedure 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . 2. Remove the engine cover, if required. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 9. Remove the carpet/mat from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8764 Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. Tighten the screws to 2 N.m (18 lb in). 4. Install the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 7. Install the engine cover, if required. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 8. Install the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) in Seats. Mat/Carpet Replacement - Rear Floor Mat/Carpet Replacement - Rear Floor Removal Procedure 1. Unsnap the seat belts from the second seat belt latches. 2. Remove the seats from the vehicle. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement Rear Bench) in Seats. 3. Remove the front and the rear door trim plates. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 4. Remove the body side front lower trim panel, if required. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 5. Remove the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. Important: The carpet bezels are retained by sonic weld and are not to be removed from the carpet. 6. Remove the carpet from the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8765 Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet into the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. Tighten the bolt to 2 N.m (18 lb in). 3. Install the body side front lower trim panel, if removed. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 4. Install the front and the rear door trim plates. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 5. Install the seats to the vehicle. Refer to Seat Replacement Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 6. Snap the seat belts to the second seat belt latches. Mat/Carpet Replacement - Rear Wheelhouse Mat/Carpet Replacement - Rear Wheelhouse Removal Procedure 1. Remove the body side trim panel. Refer to the following procedures: * Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) * Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) * Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) 2. Remove the wheelhouse carpet from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8766 Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the wheelhouse carpet to the vehicle. 2. Install the body side trim panel. Refer to the following procedures: * Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) * Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) * Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) Mat Replacement - Side Door Stepwell Mat Replacement - Side Door Stepwell Removal Procedure 1. Remove the carpet retainer. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 2. Remove the screws. 3. Remove the step panel cover. Installation Procedure 1. Install the step panel cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8767 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the step panel cover screws. Tighten the step panel cover screws to 2 N.m (18 lb in). 3. Install the carpet retainer. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation Console: Description and Operation Overhead Console Description The overhead console is a convenience package that contains the following components: * A digital display (4) that provides: * The outside temperature * Eight primary compass readings indicating the direction the vehicle is travelling * Two switches (3) including: * An ON/OFF switch for the temperature/compass display * A U.S./METRIC switch that changes the temperature readout from degrees Fahrenheit (F) to degrees Celsius (C) * Two pivoting courtesy/map lamps (1) * A compartment (4) for a garage door opener with a transmitter (2) that can be activated by pressing the button (3) on the compartment door. * A compartment for storing sunglasses * A compartment for storing compact discs or tapes For more information on the overhead console, refer to Driver Information Center (DIC) Description and Operation See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Description and Operation in Instrument Panel, Gages and Console. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat Console: Service and Repair Center Console Replacement - Rear Seat Center Console Replacement - Rear Seat Removal Procedure 1. Remove the hog rings retaining the carpet to the seat cushion frame. 2. Remove the carpet covering the center of the seat cushion frame along the rear edge of the seat, under the console. 3. Remove the bolts retaining the console to the seat cushion frame. 4. Remove the console and drink tray from the seat cushion frame. Installation Procedure 1. Install the console and drink tray to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts retaining the console and drink tray the seat cushion frame. Tighten the bolts retaining the console and drink tray to the seat cushion frame to 4 N.m (35 lb in). 3. Install the carpet covering the center of the seat cushion frame along the rear edge of the seat, under the console. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8773 4. Install the hog rings in order to retain the carpet to the frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8774 Console: Service and Repair Console Replacement - Overhead Console Replacement - Overhead Removal Procedure Because the compass system is so complex and susceptible to outside influences, examine the system thoroughly before performing any repairs. Diagnose the system in an area free from potential interference, such as an open field. Recalibrate the system before performing any other repairs in order to verify the existence of a problem. Refer to Electronic Compass Calibration See: Instrument Panel, Gauges and Warning Indicators/Compass/Service and Repair in Instrument Panel, Gages and Console. 1. Remove the retaining screws from the overhead console. 1. Remove the dome lamp lens from the overhead console. 2. Remove the front screws from the overhead console. 3. Remove the rear screws from the overhead console. 2. Disconnect the electrical connectors. 3. Remove the overhead console as follows: 1. Swing the overhead console downward. 2. Pull the overhead console forward in order to clear the rear mounting tabs. Installation Procedure 1. Install the rear part of the overhead console by inserting the mounting tabs into the roof panel. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the overhead console retaining screws. Tighten the screws to the overhead console to 2 N.m (18 lb in). 1. Install the rear screws to the overhead console . Tighten the rear screws to the overhead console to 2 N.m (18 lb in). 2. Install the front screws to the overhead console . Tighten the front screws to the overhead console to 2 N.m (18 lb in). 3. Install the dome lamp lens to the overhead console . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8775 Console: Service and Repair Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the 4-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. 5 types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8776 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8777 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11 .Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8778 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT: Use a paste type grease, not a spray, for the following step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8779 Console: Service and Repair Trim Panel Replacement - Rear Door (Cargo Doors) Trim Panel Replacement - Rear Door (Cargo Doors) Removal Procedure 1. Remove the window garnish molding. Refer to Window Garnish Molding Replacement (See: Trim Panel/Service and Repair/Window Garnish Molding Replacement) . 2. Remove the screws. 3. Remove the trim panel. Installation Procedure 1. Install the trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the trim panel screws. Tighten the trim panel screws to 2 N.m (18 lb in). 3. Install the window garnish molding. Refer to Window Garnish Molding Replacement (See: Trim Panel/Service and Repair/Window Garnish Molding Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8780 Console: Service and Repair Trim Panel Replacement - Rear Door (E54) Trim Panel Replacement - Rear Door (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the lace. 2. Use J 38778 in order to remove the trim panel. Installation Procedure 1. Install the trim panel to the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8781 2. Install the lace. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8787 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor connector (1) located on the frame crossmember. 7. Disconnect the inflatable restraint front end discriminating sensor connector. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8788 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8789 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 7. Disconnect the I/P module yellow 2-way connector (1). Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8790 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8791 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connector to the inflatable restraint front end discriminating sensor (1) located on the frame crossmember. 2. Install the CPA to the inflatable restraint front end discriminating sensor connector. 3. Install the AIR BAG fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8792 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6 Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8793 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the passenger knee bolster. 5. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8794 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the passenger knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation Glove Compartment Lock Cylinder: Description and Operation KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the 4-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. 5 types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 8799 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 8800 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11 .Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 8801 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT: Use a paste type grease, not a spray, for the following step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 8802 Glove Compartment Lock Cylinder: Service and Repair KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the 4-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. 5 types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 8803 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 8804 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11 .Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 8805 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT: Use a paste type grease, not a spray, for the following step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner Replacement Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Removal Procedure 1. Remove the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair/Removal and Replacement) . 2. Remove the overhead console, if equipped. Refer to Console Replacement - Overhead (See: Console/Service and Repair/Console Replacement - Overhead) . 3. Remove the necessary moldings. Refer to the following procedures: * Garnish Molding Replacement - Rear Upper (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) * Garnish Molding Replacement - Side Door Opening Frame (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Side Door Opening Frame) * Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) * Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) * Trim Replacement - Third Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Left) * Trim Replacement - Third Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Right) * Trim Replacement - Fourth Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Left) * Trim Replacement - Fourth Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Right) 4. Remove the right seat belt retractor. Refer to Seat Belt Retractor Replacement - Right Front in Seat Belts. 5. Remove the dome lamp from the front headliner. Refer to Dome Lamp Replacement in Lighting Systems. 6. Remove the sliding door track garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) . 7. Remove the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair/Removal and Replacement) . 8. Remove the front headliner from the roof panel by separating the retaining strips. 9. With the aid of an assistant, remove the front headliner from the vehicle. 10. Remove the 2 push-in retainers (4) at the front edge of the rear headliner (2). 11. Detach the rear headliner (2) from the retaining strips (3). 12. Remove the rear headliner (2) from the roof panel (1). Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 8809 1. Install the rear headliner to the retaining strips. 2. Install the 2 push-in retainers at the front edge of the rear headliner. 3. With the aid of an assistant, install the front headliner. 4. Fasten the front headliner to the roof panel, ensuring that the retaining strips are fully engaged. 5. Install the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair/Removal and Replacement) . 6. Install the sliding door track garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) . 7. Install the dome lamp to the front headliner. Refer to Dome Lamp Replacement in Lighting Systems. 8. Install the right seat belt retractor. Refer to Seat Belt Retractor Replacement - Right Front in Seat Belts. 9. Install the necessary moldings. Refer to the following procedures: * Trim Replacement - Fourth Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Right) * Trim Replacement - Fourth Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Left) * Trim Replacement - Third Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Right) * Trim Replacement - Third Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Left) * Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) * Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) * Garnish Molding Replacement - Rear Upper (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) * Garnish Molding Replacement - Side Door Opening Frame (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Side Door Opening Frame) 10. Install the overhead console. Refer to Console Replacement - Overhead (See: Console/Service and Repair/Console Replacement - Overhead) . 11. Install the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair/Removal and Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair Instrument Panel (I/P) Assist Handle Replacement Removal Procedure 1. Remove the inflatable restraint IP module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR. 2. Remove the nuts from the assist handle. 3. Remove the assist handle. Installation Procedure 1. Install the assist handle to the instrument panel. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist handle nuts. Tighten the assist handle nuts to 8 N.m (71 lb ft). 3. Install the inflatable restraint IP module. Refer toInflatable Restraint Instrument Panel Module Replacement in SIR. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures Sun Visor: Procedures SUNSHADE REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunshade retaining screws, unplug the wiring harness (if equipped). 2. Remove the sunshade from the vehicle. INSTALLATION PROCEDURE 1. Install the sunshade to the vehicle. 2. Install the sunshade retaining screws, connect the sunshade wiring harness (if equipped). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunshade retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures > Page 8817 Sun Visor: Removal and Replacement Sunshade Replacement Removal Procedure 1. Remove the sunshade retaining screws, unplug the wiring harness (if equipped). 2. Remove the sunshade from the vehicle. Installation Procedure 1. Install the sunshade to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the sunshade retaining screws, connect the sunshade wiring harness (if equipped). Tighten the sunshade retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement Trim Panel: Service and Repair Garnish Molding Replacement Garnish Molding Replacement - LF Lock Pillar GARNISH MOLDING REPLACEMENT - LF LOCK PILLAR REMOVAL PROCEDURE 1. Remove the retaining screw from the garnish molding. 2. Remove the driver's side seat belt upper mounting bolt. 3. Pull back on the garnish molding in order to release the fasteners. 4. Remove the garnish molding from the pillar. INSTALLATION PROCEDURE 1. Install the garnish molding to the pillar: 1.1. Align the locator pin with the pillar. 1.2. Press the locator pin firmly into place, seating all fasteners. 2. Install the driver's seat belt upper mounting bolt. 3. Install the garnish molding retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the garnish molding retaining screw to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8822 Garnish Molding Replacement - Rear Upper GARNISH MOLDING REPLACEMENT - REAR UPPER REMOVAL PROCEDURE 1. Remove the screws that retain the door frame garnish molding to the vehicle. 2. Remove the door frame garnish molding. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the molding to the roof. 3. Install the roof retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the roof retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - RF Lock Pillar GARNISH MOLDING REPLACEMENT - RF LOCK PILLAR REMOVAL PROCEDURE 1. Remove the garnish molding screws. 2. Remove the front passenger's seat belt upper retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8823 3. Remove the bolts that retain the assist handle to the pillar. 4. Pull back on the garnish molding to release the fasteners. 5. Remove the garnish molding. 6. Disconnect the electrical connector from the rear side door stepwell lamp. INSTALLATION PROCEDURE 1. Connect the electrical connector to the rear side door stepwell lamp. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8824 2. Install the molding to the pillar: 2.1. Align the fasteners with the slots in the pillar. 2.2. Press firmly until the fasteners are fully seated. 3. Install the bolts that retain the assist handle to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts that retain the assist handle to the pillar to 8 N.m (71 lb in). 4. Install the front passenger's seat belt upper retainer. 5. Install the retaining screws. Tighten Tighten the retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - Side Door Opening Frame GARNISH MOLDING REPLACEMENT - SIDE DOOR OPENING FRAME TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the garnish molding screw. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8825 2. Use the J 38778 in order to remove the door opening garnish molding on the retainers at the windshield pillar. 3. Remove the molding from one retainer in the center of the door opening. This retainer will stay with the vehicle, not the molding. 4. Slide the molding up past the following components in order to remove the molding from the vehicle: - The cowl side trim panel - The knee bolster - The instrument panel INSTALLATION PROCEDURE 1. Slide the molding past the following components in order to install the molding to the vehicle: - The instrument panel - The knee bolster - Behind the cowl side panel trim 2. Align the fasteners at the windshield pillar. 3. Press the fasteners into place until the fasteners seat fully. 4. Install the tab on the molding in the clip in the center of the door opening. 5. Install the screw that retains the end of the molding to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw that retains the end of the molding to 2 N.m (18 lb in). Garnish Molding Replacement - Sliding Door GARNISH MOLDING REPLACEMENT - SLIDING DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the swing-out window latch from the door, if equipped. 2. Remove the door handle bezel screws. 3. Remove the door handle bezel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8826 4. Use J 38778 in order to release the molding retainers. INSTALLATION PROCEDURE 1. Install the door garnish molding to the vehicle: 1.1. Align the retainers to the holes in the door. 1.2. Press the panel in order to engage the retainers into the door. 2. Install the door handle bezel to the door. 3. Install the door handle bezel screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door handle bezel screws to 2 N.m (18 lb in). 4. Install the swing-out window latch to the door, if equipped. Garnish Molding Replacement - Upper Roller Track GARNISH MOLDING REPLACEMENT - UPPER ROLLER TRACK TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the retaining screws from the upper garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8827 2. Use J 38778 in order to release the molding retainers. INSTALLATION PROCEDURE 1. Align the fasteners with the slots in the body. 2. Press the panel firmly into position, ensuring that all fasteners are fully seated. 3. Install the retaining screws to the upper garnish molding. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to the upper garnish molding to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8828 Trim Panel: Service and Repair Garnish Molding Replacement - LF Lock Pillar Garnish Molding Replacement - LF Lock Pillar Removal Procedure 1. Remove the retaining screw from the garnish molding. 2. Remove the driver's side seat belt upper mounting bolt. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 3. Pull back on the garnish molding in order to release the fasteners. 4. Remove the garnish molding from the pillar. Installation Procedure 1. Install the garnish molding to the pillar: 1. Align the locator pin with the pillar. 2. Press the locator pin firmly into place, seating all fasteners. 2. Install the driver's seat belt upper mounting bolt. Refer toShoulder Belt Guide Adjuster Replacement - Front Seat Belts. Notice: Refer toFastener Notice in Cautions and Notices. 3. Install the garnish molding retaining screw. Tighten the garnish molding retaining screw to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8829 Trim Panel: Service and Repair Garnish Molding Replacement - Lift Gate Garnish Molding Replacement - Lift Gate Removal Procedure 1. Remove the interior handle screw cover (12). 2. Remove the screws (11). 3. Remove the handle (10) and the escutcheon (9). 4. Remove the garnish molding screws (3). 5. Remove the garnish molding (2). Installation Procedure 1. Install the garnish molding (2). Install the locator pins into the locator hole on the liftgate. Notice: Refer to Fastener Notice in Caution and Notices. 2. Install the garnish molding screws (3). Tighten the garnish molding screws to 2 N.m (18 lb in). 3. Install the handle escutcheon (9) and the handle (10). 4. Install the interior handle. Tighten the interior handle screws to 6 N.m (53 lb in). 5. Install the interior handle screw covers (12). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8830 Trim Panel: Service and Repair Garnish Molding Replacement - Rear Upper Garnish Molding Replacement - Rear Upper Removal Procedure 1. Remove the screws that retain the door frame garnish molding to the vehicle. 2. Remove the door frame garnish molding. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the molding to the roof. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the roof retaining screws. Tighten the roof retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8831 Trim Panel: Service and Repair Garnish Molding Replacement - LF Lock Pillar GARNISH MOLDING REPLACEMENT - LF LOCK PILLAR REMOVAL PROCEDURE 1. Remove the retaining screw from the garnish molding. 2. Remove the driver's side seat belt upper mounting bolt. 3. Pull back on the garnish molding in order to release the fasteners. 4. Remove the garnish molding from the pillar. INSTALLATION PROCEDURE 1. Install the garnish molding to the pillar: 1.1. Align the locator pin with the pillar. 1.2. Press the locator pin firmly into place, seating all fasteners. 2. Install the driver's seat belt upper mounting bolt. 3. Install the garnish molding retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the garnish molding retaining screw to 2 N.m (18 lb in). Garnish Molding Replacement - Rear Upper Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8832 GARNISH MOLDING REPLACEMENT - REAR UPPER REMOVAL PROCEDURE 1. Remove the screws that retain the door frame garnish molding to the vehicle. 2. Remove the door frame garnish molding. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the molding to the roof. 3. Install the roof retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the roof retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - RF Lock Pillar GARNISH MOLDING REPLACEMENT - RF LOCK PILLAR REMOVAL PROCEDURE 1. Remove the garnish molding screws. 2. Remove the front passenger's seat belt upper retainer. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8833 3. Remove the bolts that retain the assist handle to the pillar. 4. Pull back on the garnish molding to release the fasteners. 5. Remove the garnish molding. 6. Disconnect the electrical connector from the rear side door stepwell lamp. INSTALLATION PROCEDURE 1. Connect the electrical connector to the rear side door stepwell lamp. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8834 2. Install the molding to the pillar: 2.1. Align the fasteners with the slots in the pillar. 2.2. Press firmly until the fasteners are fully seated. 3. Install the bolts that retain the assist handle to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts that retain the assist handle to the pillar to 8 N.m (71 lb in). 4. Install the front passenger's seat belt upper retainer. 5. Install the retaining screws. Tighten Tighten the retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - Side Door Opening Frame GARNISH MOLDING REPLACEMENT - SIDE DOOR OPENING FRAME TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the garnish molding screw. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8835 2. Use the J 38778 in order to remove the door opening garnish molding on the retainers at the windshield pillar. 3. Remove the molding from one retainer in the center of the door opening. This retainer will stay with the vehicle, not the molding. 4. Slide the molding up past the following components in order to remove the molding from the vehicle: - The cowl side trim panel - The knee bolster - The instrument panel INSTALLATION PROCEDURE 1. Slide the molding past the following components in order to install the molding to the vehicle: - The instrument panel - The knee bolster - Behind the cowl side panel trim 2. Align the fasteners at the windshield pillar. 3. Press the fasteners into place until the fasteners seat fully. 4. Install the tab on the molding in the clip in the center of the door opening. 5. Install the screw that retains the end of the molding to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw that retains the end of the molding to 2 N.m (18 lb in). Garnish Molding Replacement - Sliding Door GARNISH MOLDING REPLACEMENT - SLIDING DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the swing-out window latch from the door, if equipped. 2. Remove the door handle bezel screws. 3. Remove the door handle bezel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8836 4. Use J 38778 in order to release the molding retainers. INSTALLATION PROCEDURE 1. Install the door garnish molding to the vehicle: 1.1. Align the retainers to the holes in the door. 1.2. Press the panel in order to engage the retainers into the door. 2. Install the door handle bezel to the door. 3. Install the door handle bezel screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door handle bezel screws to 2 N.m (18 lb in). 4. Install the swing-out window latch to the door, if equipped. Garnish Molding Replacement - Upper Roller Track GARNISH MOLDING REPLACEMENT - UPPER ROLLER TRACK TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the retaining screws from the upper garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8837 2. Use J 38778 in order to release the molding retainers. INSTALLATION PROCEDURE 1. Align the fasteners with the slots in the body. 2. Press the panel firmly into position, ensuring that all fasteners are fully seated. 3. Install the retaining screws to the upper garnish molding. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to the upper garnish molding to 2 N.m (18 lb in). Garnish Molding Replacement - LF Lock Pillar Garnish Molding Replacement - LF Lock Pillar Removal Procedure 1. Remove the retaining screw from the garnish molding. 2. Remove the driver's side seat belt upper mounting bolt. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 3. Pull back on the garnish molding in order to release the fasteners. 4. Remove the garnish molding from the pillar. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8838 1. Install the garnish molding to the pillar: 1. Align the locator pin with the pillar. 2. Press the locator pin firmly into place, seating all fasteners. 2. Install the driver's seat belt upper mounting bolt. Refer toShoulder Belt Guide Adjuster Replacement - Front Seat Belts. Notice: Refer toFastener Notice in Cautions and Notices. 3. Install the garnish molding retaining screw. Tighten the garnish molding retaining screw to 2 N.m (18 lb in). Garnish Molding Replacement - Lift Gate Garnish Molding Replacement - Lift Gate Removal Procedure 1. Remove the interior handle screw cover (12). 2. Remove the screws (11). 3. Remove the handle (10) and the escutcheon (9). 4. Remove the garnish molding screws (3). 5. Remove the garnish molding (2). Installation Procedure 1. Install the garnish molding (2). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8839 Install the locator pins into the locator hole on the liftgate. Notice: Refer to Fastener Notice in Caution and Notices. 2. Install the garnish molding screws (3). Tighten the garnish molding screws to 2 N.m (18 lb in). 3. Install the handle escutcheon (9) and the handle (10). 4. Install the interior handle. Tighten the interior handle screws to 6 N.m (53 lb in). 5. Install the interior handle screw covers (12). Garnish Molding Replacement - Rear Upper Garnish Molding Replacement - Rear Upper Removal Procedure 1. Remove the screws that retain the door frame garnish molding to the vehicle. 2. Remove the door frame garnish molding. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the molding to the roof. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the roof retaining screws. Tighten the roof retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - RF Lock Pillar Garnish Molding Replacement - RF Lock Pillar Removal Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8840 1. Remove the garnish molding screws. 2. Remove the front passenger's seat belt upper retainer. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 3. Remove the bolts that retain the assist handle to the pillar. 4. Pull back on the garnish molding to release the fasteners. 5. Remove the garnish molding. 6. Disconnect the electrical connector from the rear side door stepwell lamp. Installation Procedure 1. Connect the electrical connector to the rear side door stepwell lamp. 2. Install the molding to the pillar: 1. Align the fasteners with the slots in the pillar. 2. Press firmly until the fasteners are fully seated. Notice: Refer to Fastener Notice Cautions and Notices. 3. Install the bolts that retain the assist handle to the pillar. Tighten the bolts that retain the assist handle to the pillar to 8 N.m (71 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8841 4. Install the front passenger's seat belt upper retainer. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 5. Install the retaining screws. Tighten the retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - Side Door Opening Frame Garnish Molding Replacement - Side Door Opening Frame Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the garnish molding screw. 2. Use the J 38778 in order to remove the door opening garnish molding on the retainers at the windshield pillar. 3. Remove the molding from one retainer in the center of the door opening. This retainer will stay with the vehicle, not the molding. 4. Slide the molding up past the following components in order to remove the molding from the vehicle: * The cowl side trim panel * The knee bolster * The instrument panel Installation Procedure 1. Slide the molding past the following components in order to install the molding to the vehicle: * The instrument panel * The knee bolster * Behind the cowl side panel trim 2. Align the fasteners at the windshield pillar. 3. Press the fasteners into place until the fasteners seat fully. 4. Install the tab on the molding in the clip in the center of the door opening. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw that retains the end of the molding to the vehicle. Tighten the screw that retains the end of the molding to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8842 Garnish Molding Replacement - Sliding Door Garnish Molding Replacement - Sliding Door Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the swing-out window latch from the door, if equipped. Refer to Window Replacement Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) . 2. Remove the door handle bezel screws. 3. Remove the door handle bezel. 4. Use J 38778 in order to release the molding retainers. Installation Procedure 1. Install the door garnish molding to the vehicle: 1. Align the retainers to the holes in the door. 2. Press the panel in order to engage the retainers into the door. 2. Install the door handle bezel to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the door handle bezel screws. Tighten the door handle bezel screws to 2 N.m (18 lb in). 4. Install the swing-out window latch to the door, if equipped. Refer to Window Replacement Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) . Garnish Molding Replacement - Upper Roller Track Garnish Molding Replacement - Upper Roller Track Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8843 Removal Procedure 1. Remove the retaining screws from the upper garnish molding. 2. Use J 38778 in order to release the molding retainers. Installation Procedure 1. Align the fasteners with the slots in the body. 2. Press the panel firmly into position, ensuring that all fasteners are fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the retaining screws to the upper garnish molding. Tighten the retaining screws to the upper garnish molding to 2 N.m (18 lb in). Trim Panel Replacement - Body Side Front Lower Trim Panel Replacement - Body Side Front Lower Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the intermediate seat. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 2. Remove the driver's door stepwell lamp cover retaining screw. 3. Remove the stepwell lamp assembly from the body side lower storage pocket. 4. Use the J 38778 in order to remove the body side front lower trim panel from the vehicle. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8844 1. Install the body side front lower trim panel to the vehicle: 1. Align the fasteners. 2. Snap the fasteners into place. 2. Install the driver's door stepwell lamp assembly to the body side lower storage pocket. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the stepwell lamp cover retaining screw. Tighten the stepwell lamp cover retaining screw to 2 N.m (18 lb in). 4. Install the intermediate seat. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. Trim Panel Replacement - Body Side Front Upper Trim Panel Replacement - Body Side Front Upper Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . 2. Remove the intermediate swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 3. Remove the retaining screw at the B pillar. 4. Use the J 38778 in order to remove the body side front upper trim panel from the vehicle. 5. Disconnect the electrical connector from the rear audio controls, if equipped. 6. Remove the rear audio controls from the trim panel. Refer to Audio Control Replacement - Rear Seat in Entertainment. Installation Procedure 1. Install the rear audio controls to the trim panel, if equipped. Refer to Audio Control Replacement - Rear Seat in Entertainment. 2. Connect the electrical connector to the rear audio controls. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8845 3. Install the body side front upper trim panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the retaining screw to the B pillar. Tighten the retaining screw to the B pillar to 2 N.m (18 lb in). 5. Install the intermediate swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 6. Install the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . Trim Panel Replacement - Cowl Side Trim Panel Replacement - Cowl Side Removal Procedure 1. Remove the screws that retain the panel to the cowl side. 2. Remove the trim panel from the vehicle. Installation Procedure 1. Install the trim panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the trim panel to the cowl side. Tighten the screws that retain the trim panel to the cowl side to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8846 Trim Panel Replacement - Left Body Side Trim Panel Replacement - Left Body Side Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the quarter panel swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 2. Remove the third and the fourth pillar trim. Refer to Trim Replacement - Third Pillar Left (See: Trim Replacement - Third Pillar Left) and Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) . 3. Remove the rear clip on the body side front lower trim panel. Refer to Trim Panel Replacement Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . 4. Remove the rear clips on the body side front trim panel, upper and lower. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) and Trim Panel Replacement - Body Side Front Upper (See: Trim Panel Replacement - Body Side Front Upper) . 5. Remove the seat belt upper anchor. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 6. Remove the cargo net bolt. 7. Use the J 38778 in order to remove the clips that retain the trim panel to the vehicle. 8. Pull the trim panel back from the body side panel. * Remove the seat belt retractor from the body side panel. Refer to appropriate procedure in Seat Belts: * Seat Belt Retractor Replacement - Left Front * Seat Belt Retractor Replacement - Right Front * Seat Belt Retractor Replacement - Right Rear * Seat Belt Retractor Replacement - No. 2 Left Rear * Seat Belt Retractor Replacement - No. 2 Right Rear 9. Squeeze the storage tray from underneath and press out in order to remove the storage tray from the trim panel. 10. Remove the trim panel from the vehicle. Installation Procedure 1. Install the panel to the vehicle. 2. Install the retractor through the trim panel. 3. Press the storage tray into place in order to install the storage tray to the trim panel. 4. Install the seat belt retractor to the body side panel. 5. Install the trim panel to the body side panel: 1. Align the retaining clips with the holes in the body. 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the cargo net bolt. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8847 Tighten the cargo net bolt to 2 N.m (18 lb in). 7. Install the seat belt upper anchor. 8. Remove the rear clip on the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . 9. Install the rear clips on the body side front trim panel, upper and lower. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) and Trim Panel Replacement - Body Side Front Upper (See: Trim Panel Replacement - Body Side Front Upper) . 10. Install the third and the fourth pillar trim. Refer to Trim Replacement - Third Pillar Right (See: Trim Replacement - Third Pillar Right) and Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) . 11. Install the quarter panel swing out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. Trim Panel Replacement - Rear Door (Cargo Door) Rear Door Trim Panel Replacement (Cargo Doors) REMOVAL 1. Remove the window garnish molding, refer to See: 2. Remove the screws. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8848 3. Remove the trim panel. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8849 1. Install the trim panel. NOTICE: Refer to Fastener Notice. 2. Install the trim panel screws. 3. Tighten the trim panel screws to 2 Nm (18 lb.in). 4. Install the window garnish molding, refer to See: Trim Panel Replacement - Rear Door (E54) Rear Door Trim Panel Replacement (E54) Tools Required J-38778 Door Trim Pad and Garnish Clip Remover REMOVAL Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8850 1. Remove the lace. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8851 2. Use J-38778 in order to remove the trim panel. INSTALLATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8852 1. Install the trim panel to the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8853 2. Install the lace. Trim Panel Replacement - Right Body Side Trim Panel Replacement - Right Body Side Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the C and the D pillar trim. Refer to Trim Replacement - Third Pillar Right (See: Trim Replacement - Third Pillar Right) and Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) . 2. Remove the jack access panel. 3. Remove the upper and the lower belt anchors. Refer to Seat Belt Retractor Replacement - No. 2 Left Rear or Seat Belt Retractor Replacement No. 2 Right Rear in Seat Belts. 4. Remove the cargo net bolt. 5. Remove the screw that retains the panel to the C pillar. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8854 6. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. Installation Procedure 1. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel down in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screw that retains the panel to the C pillar. Tighten the screw that retains the panel to the C pillar to 2 N.m (18 lb in). 3. Install the cargo net bolt. Tighten the cargo net bolt to 2 N.m (18 lb in). 4. Install the jack access panel. 5. Install the upper and the lower mounting bolts for the rear seat belt. Refer to Seat Belt Retractor Replacement - No. 2 Left Rear Seat Belt Retractor Replacement - No. 2 Right Rear in seat belts. 6. Install the C and the D pillar trim. Refer to the appropriate procedure: * Trim Replacement - Third Pillar Right (See: Trim Replacement - Third Pillar Right) * Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) Trim Panel Vent Replace - Body Side Front Lower Trim Panel Vent Replace - Body Side Front Lower Removal Procedure Pull out ward on the vent in order to remove the vent from the trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8855 Installation Procedure Press the vent inward in order to install the vent to the trim panel. Trim Replacement - Fourth Pillar Left Trim Replacement - Fourth Pillar Left Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the rear door(s). 2. Remove the screws from the panel in the rear door opening. 3. Use J 38778 in order to release the fasteners that retain the panel to the vehicle. 4. Disconnect the speaker electrical connector, if equipped. Installation Procedure 1. Connect the speaker electrical connector, if equipped. 2. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel down in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the panel in the rear door opening. Tighten the screws to the panel in the rear door opening to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8856 Trim Replacement - Fourth Pillar Right Trim Replacement - Fourth Pillar Right Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the rear door(s). 2. Remove the screws from the panel in the rear door opening. 3. Use J 38778 in order to release the fasteners that retain the panel to the vehicle. 4. Disconnect the speaker electrical connector, if equipped. Installation Procedure 1. Connect the speaker electrical connector, if equipped. 2. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel down in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the panel in the rear door opening. Tighten the screws to the panel in the rear door opening to 2 N.m (18 lb in). Trim Replacement - Third Pillar Left TRIM REPLACEMENT - THIRD PILLAR LEFT TOOLS REQUIRED J 38778Door Pad Trim and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the seat belt upper mount. 2. Remove the retaining screw. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8857 3. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. INSTALLATION PROCEDURE 1. Install the panel to the vehicle: 1.1. Align the retaining clips with the holes in the body. 1.2. Press the panel in order to seat the fasteners into place. 2. Install the retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screw to 2 N.m (18 lb in). 3. Install the seat belt upper mount. Trim Replacement - Third Pillar Right TRIM REPLACEMENT - THIRD PILLAR RIGHT TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover. REMOVAL PROCEDURE 1. Remove the C- pillar retaining screw. 2. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8858 INSTALLATION PROCEDURE 1. Install the panel to the vehicle: 1.1. Align the C- pillar retaining clips with the holes in the body. 1.2. Press the panel in order to seat the fasteners into place. 2. Install the C- pillar retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the C- pillar retaining screw to 2 N.m (18 lb in). Trim Replacement - Third Pillar Left Trim Replacement - Third Pillar Left Tools Required J 38778 Door Pad Trim and Garnish Clip Remover Removal Procedure 1. Remove the seat belt upper mount. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 2. Remove the retaining screw. 3. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. Installation Procedure 1. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8859 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the retaining screw. Tighten the retaining screw to 2 N.m (18 lb in). 3. Install the seat belt upper mount. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. Trim Replacement - Third Pillar Right Trim Replacement - Third Pillar Right Tools Required J 38778 Door Trim Pad and Garnish Clip Remover. Removal Procedure 1. Remove the C- pillar retaining screw. 2. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. Installation Procedure 1. Install the panel to the vehicle: 1. Align the C- pillar retaining clips with the holes in the body. 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the C- pillar retaining screw. Tighten the C- pillar retaining screw to 2 N.m (18 lb in). Window Garnish Molding Replacement Window Garnish Molding Replacement Removal Procedure 1. Remove the swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8860 Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 2. Remove the screws that retain the right molding on the sides and the bottom. 3. Remove the screws that retain the left molding on the sides and the bottom. 4. Remove the molding from the door in the area of the retainers. There are 2 retainers on top, one in the center of the panel, and 6 around the outside edge. Installation Procedure 1. Install the left molding to the door: 1. Place the retainers into the holes. 2. Press on the panel at the retainer locations until the retainers are fully seated. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement > Page 8861 2. Install the right molding to the door: 1. Place the retainers into the holes. 2. Press on the panel at the retainer locations until the retainers are fully seated. Notice: Refer to Fastener Notice 3. Install the screws that retain the panel to the door. Tighten the screws that retain the panel to the door to 2 N.m (18 lb in). 4. Install the swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 5. Ensure that the weatherstrip fits into the corner and matches the corner of the radius of the body flange. 6. Ensure that the weatherstrip is seated completely onto the flange in all areas, resulting in a smooth, vinyl trim around the entire door opening. Important: When using the rubber mallet, the weatherstrip must be hit square to the flange. Otherwise, an undesirable spreading of the carrier will occur, resulting in reduced retention. 7. Ensure that there is no distortion or excessive spreading of the carrier as a result of hitting the carrier improperly with the rubber mallet. 8. Lubricate the weatherstrip with GM Weatherstrip Silicone Lubricant P/N 12345579 or equivalent. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures Door Lock Cylinder: Procedures Outside Handle and Lock Cylinder Replacement OUTSIDE HANDLE AND LOCK CYLINDER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: If door lock cylinders require replacement for any reason, apply a coating of GM P/N 12346241 or equivalent lubricant inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door. 3. Remove the access hole plug (1). 4. Remove the lock rod from the door handle. 5. Remove the nuts from the door handle (4). 6. Remove the door handle from the door (2). 7. Remove the lock rod from the lock cylinder (3). 8. Remove the lock cylinder retainer. 9. Remove the lock cylinder and the gasket (5) from the door. INSTALLATION PROCEDURE 1. Install the gasket (5) and the lock cylinder to the door. IMPORTANT: Install new plastic retainer clips whenever the lock rods are removed. 2. Install the lock cylinder retainer. 3. Install the lock rod to the lock cylinder. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8868 4. Install the handle to the door (2). 5. Install the nuts to the door handle (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to the door handle to 6 N.m (53 lb in). 6. Install the door handle lock rod to the handle. 7. Install the access hole plug (1). 8. Install the water deflector. 9. Install the trim panel. Lock Cylinder Replacement - Sliding Door LOCK CYLINDER REPLACEMENT - SLIDING DOOR REMOVAL PROCEDURE IMPORTANT: If door lock cylinders require replacement for any reason, apply a coating of lubricant GM P/N 12346241 or equivalent to the inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. 2. Remove the water deflector. 3. Remove the lock rod from the lock cylinder (3). 4. Remove the lock rod retainer (1). 5. Remove the lock cylinder and gasket (2). INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8869 1. Code the new lock cylinder. Refer to Key and Lock Cylinder Coding in General Information. 2. Install the lock cylinder and gasket to the door (2). 3. Install the lock cylinder retainer (1). 4. Use GM P/N 12345996, Canadian P/N 10953501, High Temperature Water Resistant Lubricant or equivalent in order to lubricate the lock rods and the lock rod guide. 5. Install the lock rod to lock cylinder (3). 6. Install the water deflector. 7. Install the trim panel. Binding Lock Cylinders BINDING LOCK CYLINDERS Apply the proper lubrication, and binding or sticking door lock cylinders and keys that are hard to insert or remove, in many cases, will be corrected. The recommended material for lubricating these components is Multi-Purpose Lubricant Superlube(R) GM P/N 12346241, Canadian P/N 70953474 or equivalent. Penetrating lubricants such as GM P/N 1052949, Canadian P/N 726548 and WD-40(R) are not recommended. These lubricants wash out the original lubrication and eventually evaporate, leaving little or no lubricating material. Refer to steps 2 through 5 below for proper methods of lubrication in order to use GM P/N 1052949, Canadian P/N 726548 or WD-40(R) in order to unfreeze or loosen lock cylinder components. Perform the following procedure in order to repair frozen lock cylinders due to cold weather: 1. Apply heat to the cylinder with a heat gun while being careful not to damage any painted surfaces. 2. Hold the door lock cylinder shutter open with a paper clip (or similar item). 3. Use compressed air and a blow gun attachment in order to force air into the cylinders. 4. Inject a small amount of lubricant into the cylinder while holding the shutter door open. Refer to the above recommendations. 5. Work the key into the cylinder several times and wipe any excess lubrication residue from the key. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8870 Door Lock Cylinder: Removal and Replacement Outside Handle and Lock Cylinder Replacement Removal Procedure Important: If door lock cylinders require replacement for any reason, apply a coating of GM P/N 12346241 or equivalent lubricant inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 3. Remove the access hole plug (1). 4. Remove the lock rod from the door handle. 5. Remove the nuts from the door handle (4). 6. Remove the door handle from the door (2). 7. Remove the lock rod from the lock cylinder (3). 8. Remove the lock cylinder retainer. 9. Remove the lock cylinder and the gasket (5) from the door. Installation Procedure Important: Install new plastic retainer clips whenever the lock rods are removed. 1. Install the gasket (5) and the lock cylinder to the door. 2. Install the lock cylinder retainer . 3. Install the lock rod to the lock cylinder. 4. Install the handle to the door (2). Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the nuts to the door handle (4). Tighten the nuts to the door handle to 6 N.m (53 lb in). 6. Install the door handle lock rod to the handle. 7. Install the access hole plug (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8871 8. Install the water deflector. Refer to Water Deflector Replacement - Front Door. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 9. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Relay > Component Information > Locations Door Lock Relay: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Relay > Component Information > Locations > Page 8875 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Relay > Component Information > Locations > Page 8876 Door Lock Relay Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8881 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8882 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8883 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair Antenna - Keyless Entry: Service and Repair KEYLESS ENTRY ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Remove the instrument panel cluster. 3. Disconnect the remote keyless entry antenna (1) from the receiver (2). 4. Remove the remote keyless entry antenna (1) from the carrier. 5. Remove the remote keyless entry antenna from the vehicle. INSTALLATION PROCEDURE 1. Install the remote keyless entry antenna to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Page 8888 2. Install the remote keyless entry antenna (1) to the carrier. 3. Connect the remote keyless entry antenna (1) to the receiver (2). 4. Install the instrument panel cluster. 5. Install the instrument panel cluster trim plate. 6. Reprogram the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Remote Control Door Lock Receiver (RCDLR) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams > Page 8892 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left knee bolster. 2. Disconnect the remote keyless entry antenna (2) from the receiver (5). 3. Disconnect the remote keyless entry electrical connector (4) from the receiver (5). 4. Remove the remote keyless entry module screws from the bracket (3). 5. Remove the remote keyless entry module from the carrier. INSTALLATION PROCEDURE 1. Install the remote keyless entry module to the carrier. 2. Install the remote keyless entry module screws to the bracket (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the remote keyless entry module screws to the bracket (3) to 2 N.m (18 lb in). 3. Connect the remote keyless entry antenna (2) to the receiver (5). 4. Connect the remote keyless entry electrical connector (4) to the receiver (5). 5. Install the left knee bolster. 6. Reprogram the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the 2 halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery (2). INSTALLATION PROCEDURE 1. Install the battery (2) with the positive (+) side down. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 8897 Use one 3 V CR2032 battery (or the equivalent). 2. Close the transmitter case (6, 4). 3. Ensure the seal is in position. Align the 2 halves of the case and snap the two halves together. 4. Synchronize the transmitter. 5. Replace the batteries when the range of the transmitter decreases to less than 7 m (23 ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Power Door Lock Actuator: Locations Front Door Wiring (Front Passenger Shown, Driver Opposite) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8902 Right D Pillar Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8903 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8904 Front Door Wiring (Front Passenger Shown, Driver Opposite) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8905 Right D Pillar Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8906 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8907 Power Door Lock Actuator: Diagrams Door Lock Actuator - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8908 Door Lock Actuator - Front Passenger Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8909 Door Lock Actuator - Rear Without RPO Code E54 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8910 Door Lock Actuator - Rear With RPO Code E54 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 8911 Door Lock Actuator - Side Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Door - 1 Power Door Lock Actuator: Service and Repair Lock Actuator Replacement - Door - 1 LOCK ACTUATOR REPLACEMENT - DOOR REMOVAL PROCEDURE 1. Remove the trim panel. 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. 3. Remove the power door lock actuator in order to remove the remote lever rod. 4. Disconnect the power door lock actuator wiring harness. 5. Use a 6 mm (1/4 in) drill bit in order to remove the actuator to door rivets. 6. Remove the actuator from the door. INSTALLATION PROCEDURE 1. Install the actuator to the door. 2. Install the actuator to door rivets. IMPORTANT: Install new plastic retainer clips whenever the lock rods are removed. 3. Connect the power door lock actuator wiring harness. 4. Install the power door lock actuator to the remote lever rod. 5. Install the water deflector. 6. Install the trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Lock Actuator Replacement - Door - 1 > Page 8914 Power Door Lock Actuator: Service and Repair Lock Actuator Replacement - Door - 2 LOCK ACTUATOR REPLACEMENT - DOOR TOOLS REQUIRED M 39010 Heavy Duty Rivet Gun REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the water deflector away from the door. 3. Remove the rod that retains the actuator to the lever. 4. Remove the actuator wiring connector. 5. Remove the rivets that retain the actuator to the door. Drill out the head of the rivet with a 5 mm (3/16 in) drill bit. 6. Remove the actuator from the door. INSTALLATION PROCEDURE 1. Install the actuator to the door. 2. Use the M 39010 in order to install the rivets that retain the actuator to the door. 3. Install the actuator wiring connector. 4. Install the actuator to the lever rod. 5. Install the water deflector. 6. Install the trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 8918 Power Door Lock Switch: Diagrams Door Lock Switch - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 8919 Door Lock Switch - Front Passenger Part 1 Door Lock Switch - Front Passenger Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 8920 Power Door Lock Switch: Service and Repair POWER ACCESSORY SWITCH PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the armrest screws and the armrest YC5. 2. Remove the window handle, if equipped. 3. Pull out on the escutcheon in order to remove the lock lever escutcheon. Start with the front edge of the escutcheon. 4. Remove the upper corner trim using the following method: 4.1. Pull the upper corner trim at the top edge. 4.2. Pivot the upper corner trim down in order to clear the tab at the trim panel, YC6 and YC7. 5. Remove the caps that cover the screws for the assist handle. 6. Remove the screws that retain the assist handle to the door. 7. Remove the screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 2. Install the plate to the trim panel. 3. Install the screw at the front edge of the accessory switch mount plate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws at the front edge of the accessory switch mount plate to 5 N.m (44 lb in). 4. Install the assist handle and screws to the door. Tighten Tighten the assist handle screws to 5 N.m (44 lb in). 5. Install the caps that cover the screws on the assist handle. 6. Insert the tab in the slot on the door trim panel. Seat the fastener into the door at the top, YC6 and YC7 in order to install the upper corner trim. 7. Snap the lock lever escutcheon into place in order to install the lock lever escutcheon. Start at the rear edge of the escutcheon. 8. Install the window handle, if equipped. 9. Install the armrest and armrest screws, YC5. Tighten Tighten the armrest screws to 5 N.m (44 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Disconnect the electrical connector. 3. Remove the rear wiper motor from the liftgate. 4. Remove the lock cylinder retainer. 5. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the lock cylinder retainer. 3. Install the rear wiper motor to the liftgate. 4. Connect the electrical connector. 5. Install the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Vehicle Personalization Memory Positioning Systems: Description and Operation Vehicle Personalization VEHICLE PERSONALIZATION PROGRAMMABLE AUTOMATIC DOOR LOCKS (IF EQUIPPED) If the vehicle has power door locks, it is equipped with a feature that enables you to program the power door locks. The vehicle left the factory programmed to automatically lock all doors when the vehicle is shifted out of PARK (P), and all doors unlock when the vehicle is shifted into PARK (P). If the vehicle has a manual transmission, it left the factory programmed to lock all doors when the vehicle speed is greater than 13 km/h (8 mph) for two seconds, and unlock all doors once the key is removed from the ignition. The following instructions detail how to enter the programming mode for the power door lock feature: 1. Begin with the ignition in OFF. Then pull the turn signal/multifunction lever all the way toward you and hold it there while you perform the next step. 2. Turn the key to RUN and OFF twice. Then, with the key in OFF, release the turn signal/multifunction lever. Once you do this, you will hear the lock switch lock and unlock. 3. You are now ready to program the automatic door locks. Select one of the following four programming options and follow the instructions. You will have 30 seconds to complete programming. If you exceed the 30 seconds limit, The locks will automatically lock and unlock to indicate that you have left the program mode. If this occurs, repeat the procedure beginning with step 1. You can exit the program mode any time by turning the ignition to RUN. If the LOCK/UNLOCK switches are not pressed while in the programming mode, the current LOCK/UNLOCK mode will not be modified. The following is a list of available programming options: - All doors lock/Only the driver's door unlocks: Press the lock side of the power door lock switch on the door panel once, and then the unlock side once. - All doors lock/All doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side twice. - All doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side three times. - No doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel twice. This turns off the automatic door lock feature. ADDITIONAL INFORMATION Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Vehicle Personalization > Page 8933 Memory Positioning Systems: Description and Operation Personalization Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization . This vehicle does not have specific driver personalization available. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8937 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8938 Outside Rearview Mirror Switch Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 8948 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 8954 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8964 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8965 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8966 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8967 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8970 WA160E/06 - WA228A/55 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8971 WA253A/86 - WA379E/86 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8972 WA379E/86 - WA382E/11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8973 WA387E/57 - WA408G/44 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8974 WA423G/79 - WA519F/12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8975 WA519F/12 - WA519F/12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8976 WA519F/12 - WA526F/72 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8977 WA526F/72 - WA528F/76 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8978 WA528F/76 - WA5322/33 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8979 WA5322/33 - WA534F/54 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8980 WA534F/54 - WA5456/43 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8981 WA605H/45 - WA711J/58 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8982 WA711J/58 - WA722J/25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8983 WA722J/25 - WA765J/37 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8984 WA765J/37 - WA800J/98 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8985 WA800J/98 - WA805K/62 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8986 WA805K/62 - WA810K/48 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8987 WA810K/48 - WA812K/88 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8988 WA812K/88 - WA813K/89 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8989 WA813K/89 - WA817K/63 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8990 WA820K/94 - WA8554/40 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8991 WA8554/40 - WA8554/40 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8992 WA8554/40 - WA8555/41 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8993 WA8555/41 - WA8555/41 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8994 WA8555/41 - WA8555/41 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8995 WA8555/41 - WA8555/41 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8996 WA8555/41 - WA8624/50 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8997 WA8624/50 - WA8624/50 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8998 WA8624/50 - WA882K/90 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 8999 WA882K/90 - WA900J/59 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9000 WA900J/59 - WA9260/74 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9001 WA9260/74 - WA9260/74 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9002 WA9260/74 - WA9539/47 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9003 WA9539/47 - WA9539/47 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9004 WA9539/47 - WA9792/39 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9005 WA9792/39 - WA990A/19U Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9006 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9007 Paint: Application and ID Parts ID Label Location LABEL - SERVICE PARTS ID Label - Service Parts ID The Service Parts Identification Label aids the service personnel in identifying the parts and options originally installed on the vehicle. The label is located on the front passenger door frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9008 Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Cautions and Notices. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D-99 identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel.) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 9009 Paint: Application and ID Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in General Information in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair Support Replacement - Center Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 2. Remove the outside air temperature sensor and wiring, if equipped. 3. Remove the center support bracket bolts. 4. Remove the support bracket from the vehicle. Installation Procedure 1. Install the center support bracket to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the support bracket bolts. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the outside air temperature sensor and wiring, if equipped. 4. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations Door Lock Relay: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 9017 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 9018 Door Lock Relay Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations Body Wiring - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations > Page 9022 Liftglass Lock/Unlock Relay Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications Luggage Rack: Specifications Fastener Tightening Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications > Page 9027 Luggage Rack: Service and Repair Luggage Carrier Replacement Removal Procedure 1. Remove the rubber side rail cap from the center support. 2. Remove the bolts from the center supports. 3. Remove the bolts from the end supports. 4. Remove the luggage carrier as an assembly from the roof with an assistant. 5. Remove the side rail support gaskets. 6. Remove the screws from the side rail supports. 7. Remove the side rail supports from the side rails. 8. Remove the screws from the cross rails. 9. Remove the cross rails from the sliders. 10. Remove the screws from the sliders and the lock plates. 11. Remove the sliders from the slots in the side rails. Installation Procedure 1. Install the sliders into the slots in the side rails. 2. Install the screws into the sliders and the lock plates. 3. Install the cross rails onto the sliders. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications > Page 9028 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the screws to the cross rails. Tighten the screws to 2 N.m (18 lb in). 5. Install the side rail supports to the side rails. 6. Install the screws to the side rail supports. Tighten the screws to 2 N.m (18 lb in). 7. Install the side rail support gaskets to the roof. 8. Install the luggage carrier as an assembly onto the roof with an assistant. 9. Install the screws to the end supports. Tighten the screws to 3 N.m (27 lb in). 10. Install the screws into the center supports. Tighten the screws to 3 N.m (27 lb in). 11. Install the rubber side rail cap onto the center support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures Head Rest: Procedures Bucket Seat Head Restraint Bushing Replacement BUCKET SEAT HEAD RESTRAINT BUSHING REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat back cover and pad. 2. Remove the headrest bushings from the seat back frame as follows: 2.1. Squeeze together the retaining tabs at the base of the bushing. 2.2. Remove the bushing by lifting the bushing up. INSTALLATION PROCEDURE 1. Install the headrest bushings by pressing the bushings into the seat back frame until the retaining tabs snap into place. 2. Install the seat back trim cover and pad assembly. Head Restraint Replacement With RPO Code YC6 HEAD RESTRAINT REPLACEMENT WITH RPO CODE YC6 REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 9037 1. Raise the headrest. 2. Using a pointed tool, release the retainer on either side of the headrest while pulling up on the headrest. 3. Remove the headrest from the seat. INSTALLATION PROCEDURE 1. Align the headrest posts with the openings in the seat back. 2. Press the headrest down into the seat to the fully lowered position. 3. Pull the headrest back up in order to assure the retainers are functioning properly. Head Restraint Replacement With RPO Code YC7 HEAD RESTRAINT REPLACEMENT WITH RPO CODE YC7 REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 9038 1. Raise the headrest. 2. If an assistant is available, proceed as follows: 2.1. Press the locking tabs on the headrest bushings in and down at a 45 degree angle in order to release them. 2.2. Have the assistant lift up on the headrest. 2.3. Remove the headrest. 3. If working alone, proceed as follows: 3.1. Using one hand, depress one locking tab. Use the other hand to lift up on that side of the headrest. 3.2. While continuing to pull up on the headrest, depress the locking tab on the other side of the headrest bushing. 3.3. Remove the headrest from the seat back. INSTALLATION PROCEDURE 1. Install the headrest to the seat back. 2. Push down on the headrest. 3. While continuing to press down on the headrest, depress the locking tab on the other side of the headrest bushing. 4. The locking tabs should click into place. Head Restraint Replacement - Rear Seat HEAD RESTRAINT REPLACEMENT - REAR SEAT REMOVAL PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 9039 1. Raise the headrest. 2. If an assistant is available, proceed as follows: 2.1. Press the locking tabs on the headrest bushings in and down at a 45 degree angle in order to release them. 2.2. Have the assistant lift up on the headrest. 2.3. Remove the headrest. 3. If working alone, proceed as follows: 3.1. Using 1 hand, depress 1 locking tab. Use the other hand to lift up on the same side of the headrest. 3.2. While continuing to pull up on the headrest, depress the locking tab on the other side of the headrest bushing. 3.3. Remove the headrest from the seat back. INSTALLATION PROCEDURE 1. Align the post of the headrest with the holes in the seat back. 2. Manipulate the posts within the seat back until the posts fall into the holes in the headrest bushing. 3. Press the headrest all the way into the seat. 4. Raise the headrest in order to verify that the locks are engaged. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 9040 Head Rest: Removal and Replacement Head Restraint Replacement - Rear Seat Head Restraint Replacement - Rear Seat Removal Procedure 1. Raise the headrest. 2. If an assistant is available, proceed as follows: 1. Press the locking tabs on the headrest bushings in and down at a 45 degree angle in order to release them. 2. Have the assistant lift up on the headrest. 3. Remove the headrest. 3. If working alone, proceed as follows: 1. Using 1 hand, depress 1 locking tab. Use the other hand to lift up on the same side of the headrest. 2. While continuing to pull up on the headrest, depress the locking tab on the other side of the headrest bushing. 3. Remove the headrest from the seat back. Installation Procedure 1. Align the post of the headrest with the holes in the seat back. 2. Manipulate the posts within the seat back until the posts fall into the holes in the headrest bushing. 3. Press the headrest all the way into the seat. 4. Raise the headrest in order to verify that the locks are engaged. Head Restraint Replacement (YC6) Head Restraint Replacement (YC6) Removal Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 9041 1. Raise the headrest. 2. Using a pointed tool, release the retainer on either side of the headrest while pulling up on the headrest. 3. Remove the headrest from the seat. Installation Procedure 1. Align the headrest posts with the openings in the seat back. 2. Press the headrest down into the seat to the fully lowered position. 3. Pull the headrest back up in order to assure the retainers are functioning properly. Head Restraint Replacement (YC7) Head Restraint Replacement (YC7) Removal Procedure 1. Raise the headrest. 2. If an assistant is available, proceed as follows: 1. Press the locking tabs on the headrest bushings in and down at a 45 degree angle in order to release them. 2. Have the assistant lift up on the headrest. 3. Remove the headrest. 3. If working alone, proceed as follows: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 9042 1. Using one hand, depress one locking tab. Use the other hand to lift up on that side of the headrest. 2. While continuing to pull up on the headrest, depress the locking tab on the other side of the headrest bushing. 3. Remove the headrest from the seat back. Installation Procedure 1. Install the headrest to the seat back. 2. Push down on the headrest. 3. While continuing to press down on the headrest, depress the locking tab on the other side of the headrest bushing. 4. The locking tabs should click into place. Bucket Seat Head Restraint Bushing Replacement Bucket Seat Head Restraint Bushing Replacement Removal Procedure 1. Remove the seat back cover and pad. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Cover and Pad Replacement (YC7)) . 2. Remove the headrest bushings from the seat back frame as follows: 1. Squeeze together the retaining tabs at the base of the bushing. 2. Remove the bushing by lifting the bushing up. Installation Procedure 1. Install the headrest bushings by pressing the bushings into the seat back frame until the retaining tabs snap into place. 2. Install the seat back trim cover and pad assembly. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Cover and Pad Replacement (YC7)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Vehicle Personalization Memory Positioning Systems: Description and Operation Vehicle Personalization VEHICLE PERSONALIZATION PROGRAMMABLE AUTOMATIC DOOR LOCKS (IF EQUIPPED) If the vehicle has power door locks, it is equipped with a feature that enables you to program the power door locks. The vehicle left the factory programmed to automatically lock all doors when the vehicle is shifted out of PARK (P), and all doors unlock when the vehicle is shifted into PARK (P). If the vehicle has a manual transmission, it left the factory programmed to lock all doors when the vehicle speed is greater than 13 km/h (8 mph) for two seconds, and unlock all doors once the key is removed from the ignition. The following instructions detail how to enter the programming mode for the power door lock feature: 1. Begin with the ignition in OFF. Then pull the turn signal/multifunction lever all the way toward you and hold it there while you perform the next step. 2. Turn the key to RUN and OFF twice. Then, with the key in OFF, release the turn signal/multifunction lever. Once you do this, you will hear the lock switch lock and unlock. 3. You are now ready to program the automatic door locks. Select one of the following four programming options and follow the instructions. You will have 30 seconds to complete programming. If you exceed the 30 seconds limit, The locks will automatically lock and unlock to indicate that you have left the program mode. If this occurs, repeat the procedure beginning with step 1. You can exit the program mode any time by turning the ignition to RUN. If the LOCK/UNLOCK switches are not pressed while in the programming mode, the current LOCK/UNLOCK mode will not be modified. The following is a list of available programming options: - All doors lock/Only the driver's door unlocks: Press the lock side of the power door lock switch on the door panel once, and then the unlock side once. - All doors lock/All doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side twice. - All doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side three times. - No doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel twice. This turns off the automatic door lock feature. ADDITIONAL INFORMATION Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Vehicle Personalization > Page 9051 Memory Positioning Systems: Description and Operation Personalization Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization . This vehicle does not have specific driver personalization available. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Seat - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 9055 Sear - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 9056 Power Seat Motor: Service and Repair SEAT ADJUSTER MOTOR REPLACEMENT - FRONT The seat adjuster motor is not a separately serviceable item. If it is necessary to replace the seat adjuster motor, replace the seat adjuster assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Sear - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9060 Seat - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9061 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9062 Seat Adjuster Switch - Driver Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 9065 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. 3. Install the screws that retain the power seat switch to the seat. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 9066 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. Installation Procedure 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 9067 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the power seat switch to the seat. Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front SEAT BACK FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the bucket seat from the vehicle. 2. Remove the seat back cover and pad. 3. Remove the lumbar support cable. 4. Remove the bolts from the seat back hinges on the right and left side. 5. Remove the seat back frame. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9073 1. Install the seat back frame. 2. Install the bolts to the seat back hinges on the right and left side. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to the seat back hinges on the right and left side to 30 N.m (22 lb in). 3. Install the lumbar support cable. 4. Install the seat back cover and pad. 5. Install the bucket seat in the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9074 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear With RPO Codes YC5 and YC6 SEAT BACK FRAME REPLACEMENT - REAR WITH RPO CODES YC5 AND YC6 REMOVAL PROCEDURE 1. Remove the bench seat from the vehicle. 2. Remove the seat back cover and pad. 3. Remove the headrest bushing. 4. Remove the rear seat latch release cable. 5. Remove the right and left seat back frame hinge bolts. 6. Remove the seat back frame. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9075 1. Install the seat back frame. 2. Install the right and left seat back frame hinge bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the right and left seat back frame hinge bolts to 30 N.m (22 lb ft). 3. Install the rear seat latch release cable. 4. Install the headrest bushing. 5. Install the seat back cover and pad. 6. Install the bench seat to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9076 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear With RPO Code YC7 SEAT BACK FRAME REPLACEMENT - REAR WITH RPO CODE YC7 REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat back cover and pad. 3. Remove the right and left bolts that retain the seat back frame to the seat back hinges. IMPORTANT: Note the position and the length of the bolts removed. This will assist with reassembly 4. Remove the seat back frame. INSTALLATION PROCEDURE 1. Install the seat back frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9077 2. Install the bolts that retain the seat back frame to the seat back hinges in the locations noted during disassembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts that retain the seat back frame to the seat back hinges to 30 N.m (22 lb ft). 3. Install the seat back cover and pad. 4. Install the bench seat in the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9082 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9083 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9084 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9085 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9086 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9087 Seat Cover: Technical Service Bulletins Interior - Napped Seat Fabric Repair Bulletin No.: 04-08-50-011A Date: May 04, 2006 INFORMATION Subject: Repairing Napped Seat Fabric Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 1999-2006 Chevrolet Silverado 2000-2007 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Astro 2002-2006 Chevrolet Monte Carlo 2002-2007 Chevrolet Avalanche 2002-2005 GMC Safari 2007 GMC Yukon, Yukon XL 2002-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Prix Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 04-08-50-011 (Section 08 - Body & Accessories). This bulletin is being issued to advise technicians/dealers on the proper repair required when a customer brings in a trimmed seat with the appearance of being worn, having a bald spot and/or being discolored. The seats in the later vehicles are trimmed with a cloth that has a napped fabric. Under some circumstances, the nap may become crushed down by normal use, giving the appearance of being worn out. If the base material is NOT visible, use a small brass (NOT STEEL) wire brush to carefully fluff and raise the nap. The wire brush (fine bristle brass) is available at most hardware and home stores. If the base material is visible, replace the trim cover. The Astro/Safari van will also have this material on the door trim. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures Seat Cushion: Procedures Seat Cushion Cover and Pad Replacement - Rear SEAT CUSHION COVER AND PAD REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the bench seat and risers from the vehicle. 2. Remove the right and left sides of the seat back hinge trim. 3. Remove the bolts retaining the seat back hinges to the seat cushion frame. IMPORTANT: Note the position and length of the bolts you remove. This will assist with reassembly. 4. Remove the J-hooks that retain the seat cushion cover to the seat cushion frame. 5. Remove the hog rings that retain the seat cushion cover to the seat cushion frame located at the rear edge of the seat frame. IMPORTANT: Note the locations of the hog rings for reassembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9092 6. Remove the seat back cushion cover and pad from the seat cushion frame. 7. Remove the hog rings that retain the seat cushion cover to the seat cushion pad located under the seat cushion cover. IMPORTANT: Note the locations of the hog rings for reassembly. 8. Remove the seat cushion cover from the seat cushion pad. INSTALLATION PROCEDURE 1. Install the seat cushion cover to the seat cushion pad. 2. Install the hog rings that retain the seat cushion cover to the seat cushion pad located under the seat cushion cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9093 3. Install the seat back cushion cover and pad to the seat cushion frame. 4. Install the hog rings that retain the seat cushion cover to the seat cushion frame located at the rear edge of the seat frame. 5. Install the J-hooks that retain the seat cushion cover to the seat cushion frame. 6. Install the bolts that retain the seat back hinges to the seat cushion frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts that retain the seat back hinges to the seat cushion frame to 30 N.m (22 lb ft). 7. Install the right and left sides of the seat back hinge trim. 8. Install the bench seat and risers in the vehicle. Seat Cushion Cover Replacement - Front With RPO Code YC7 SEAT CUSHION COVER REPLACEMENT - FRONT WITH RPO CODE YC7 REMOVAL PROCEDURE 1. Remove the bucket seat from the seat risers. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9094 2. Remove the bolts that retain the seat back hinges to the seat cushion frame. IMPORTANT: Note the position and length of the bolts you remove. This will assist with reassembly. 3. Remove the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. 4. Remove the hog rings that retain the seat cushion cover and pad to the seat cushion frame. IMPORTANT: Note the locations of the hog rings for reassembly. 5. Remove the seat cushion cover and pad from the seat cushion frame. 6. Remove the hog rings that retain the seat cushion cover to the pad. IMPORTANT: Note the locations of the hog rings for reassembly. 7. Remove the seat cushion cover from the pad. INSTALLATION PROCEDURE 1. Install the seat cushion cover to the pad. 2. Install the hog rings that retain the seat cushion cover to the pad in the locations noted during disassembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9095 3. Install the seat cushion cover and the pad to the seat cushion frame. 4. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 5. Install the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. 6. Install the bolts that retain the seat back hinges to the seat cushion frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 30 N.m (22 lb ft). 7. Install the bucket seat to the seat risers. Seat Cushion Cover Replacement - Front RPO Codes YC5 and YC6 SEAT CUSHION COVER REPLACEMENT-FRONT WITH RPO CODES YC5 AND YC6 REMOVAL PROCEDURE 1. Remove the bucket seat from the seat risers. 2. Remove the screw from the recliner lever handle if equipped. 3. Remove the lever from the recliner if equipped. 4. Remove the lumbar knob and clip if equipped. 5. Remove the J-hooks that retain the seat cushion cover to the seat cushion frame. 6. Remove the hog rings that retain the seat cushion cover to the seat cushion frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9096 IMPORTANT: Note the positions of the hog rings for reassembly. 7. Remove the seat cushion cover and pad from the seat cushion frame. 8. Remove the seat cushion cover from the pad. INSTALLATION PROCEDURE 1. Install the seat cushion cover to the pad. 2. Install the seat cushion cover and the pad to the seat cushion frame. 3. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 4. Install the J-hook that retain the seat cushion cover to the seat cushion frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9097 5. Install the lumbar knob and clip if equipped. 6. Install the lever to the recliner if equipped. 7. Install the screw to the recliner lever handle if equipped. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to the recliner lever handle to 2 N.m (18 lb in). 8. Install the bucket seat to the seat risers. With RPO Code YC7 SEAT CUSHION FRAME REPLACEMENT - REAR WITH RPO CODE YC7 REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat cushion cover and pad. 3. Remove the bolts retaining the seat back hinges to the seat cushion frame. IMPORTANT: Note the position and length of the bolts removed. This will assist with reassembly. 4. Remove the bolts retaining the console to the seat cushion frame. IMPORTANT: Note the position and length of the bolts removed. This will assist with reassembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9098 5. Remove the seat cushion frame. INSTALLATION PROCEDURE 1. Install the seat cushion frame. 2. Install the bolts that retain the console to the seat cushion frame in the locations noted during disassembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts that retain the console to the seat cushion frame to 30 N.m (22 lb ft). 3. Install the bolts that retain the seat back hinges to the seat cushion frame in the locations noted during disassembly. Tighten Tighten the bolts that retain the seat back hinges to the bench seat cushion frame to 30 N.m (22 lb ft). 4. Install the seat cushion cover and pad. 5. Install the rear bench seat to the vehicle. With RPO Code YC5 and YC6 SEAT CUSHION FRAME REPLACEMENT - REAR WITH RPO CODES YC5 AND YC6 REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat cushion cover and pad. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9099 3. Remove the seat back hinge bolts from the right and left sides of the cushion frame. 4. Remove the seat cushion frame. INSTALLATION PROCEDURE 1. Install the seat cushion frame. 2. Install the seat back hinge bolts to the right and left sides of the seat cushion frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat back hinge bolts to the right and left sides of the seat cushion frame 30 N.m (22 lb ft). 3. Install the seat cushion cover and pad. 4. Install the rear bench seat to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9100 Seat Cushion Frame Replacement SEAT CUSHION FRAME REPLACEMENT REMOVAL PROCEDURE 1. Remove the bucket seat from the vehicle. 2. Remove the seat cushion cover and pad. 3. Remove Lumbar support cable. 4. Remove the seat back hinge bolts from the right side of the seat frame. 5. Remove the seat back hinge bolts from the left side of the seat frame. 6. Remove the seat cushion frame from the seat back frame. INSTALLATION PROCEDURE 1. Install the seat cushion frame to the seat back frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9101 2. Install the seat back hinge bolts to the left side of the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat back hinge bolts to the left side of the seat frame to 30 N.m (22 lb ft). 3. Install the bolts to the right side of the seat frame. Tighten Tighten the seat back hinge bolts to the right side of the seat frame to 30 N.m (22 lb ft). 4. Install the lumbar support cable. 5. Install the seat cushion cover and pad. 6. Install the bucket seat in the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9102 Seat Cushion: Removal and Replacement Seat Cushion Cover Replacement - Front (YC5 and YC6) Seat Cushion Cover Replacement - Front (YC5 and YC6) Removal Procedure 1. Remove the bucket seat from the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the screw from the recliner lever handle if equipped. 3. Remove the lever from the recliner if equipped. 4. Remove the lumbar knob and clip if equipped. 5. Remove the J-hooks that retain the seat cushion cover to the seat cushion frame. Important: Note the positions of the hog rings for reassembly. 6. Remove the hog rings that retain the seat cushion cover to the seat cushion frame. 7. Remove the seat cushion cover and pad from the seat cushion frame. 8. Remove the seat cushion cover from the pad. Installation Procedure 1. Install the seat cushion cover to the pad. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9103 2. Install the seat cushion cover and the pad to the seat cushion frame. 3. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 4. Install the J-hook that retain the seat cushion cover to the seat cushion frame. 5. Install the lumbar knob and clip if equipped. 6. Install the lever to the recliner if equipped. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the screw to the recliner lever handle if equipped. Tighten the screw to the recliner lever handle to 2 N.m (18 lb in). 8. Install the bucket seat to the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Cushion Cover Replacement - Front (YC7) Seat Cushion Cover Replacement - Front (YC7) Removal Procedure 1. Remove the bucket seat from the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Important: Note the position and length of the bolts you remove. This will assist with reassembly. 2. Remove the bolts that retain the seat back hinges to the seat cushion frame. Refer to Seat Back Frame Replacement - Front (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Frame Replacement - Front) . 3. Remove the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. Important: Note the locations of the hog rings for reassembly. 4. Remove the hog rings that retain the seat cushion cover and pad to the seat cushion frame. 5. Remove the seat cushion cover and pad from the seat cushion frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9104 Important: Note the locations of the hog rings for reassembly. 6. Remove the hog rings that retain the seat cushion cover to the pad. 7. Remove the seat cushion cover from the pad. Installation Procedure 1. Install the seat cushion cover to the pad. 2. Install the hog rings that retain the seat cushion cover to the pad in the locations noted during disassembly. 3. Install the seat cushion cover and the pad to the seat cushion frame. 4. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 5. Install the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the bolts that retain the seat back hinges to the seat cushion frame. Tighten the bolts to 30 N.m (22 lb ft). 7. Install the bucket seat to the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Cushion Frame Replacement Seat Cushion Frame Replacement Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover Replacement - Front (YC5 and YC6) (See: Seat Cushion Cover Replacement - Front (YC5 and YC6))Seat Cushion Cover Replacement - Front (YC7) (See: Seat Cushion Cover Replacement - Front (YC7)) . 3. Remove Lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9105 4. Remove the seat back hinge bolts from the right side of the seat frame. 5. Remove the seat back hinge bolts from the left side of the seat frame. 6. Remove the seat cushion frame from the seat back frame. Installation Procedure 1. Install the seat cushion frame to the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat back hinge bolts to the left side of the seat frame. Tighten the seat back hinge bolts to the left side of the seat frame to 30 N.m (22 lb ft). 3. Install the bolts to the right side of the seat frame. Tighten the seat back hinge bolts to the right side of the seat frame to 30 N.m (22 lb ft). 4. Install the lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . 5. Install the seat cushion cover and pad . Refer to Seat Cushion Cover Replacement - Front (YC5 and YC6) (See: Seat Cushion Cover Replacement - Front (YC5 and YC6))Seat Cushion Cover Replacement - Front (YC7) (See: Seat Cushion Cover Replacement - Front (YC7)) . 6. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Cushion Frame Replacement - Rear (YC5 and YC6) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9106 Seat Cushion Frame Replacement - Rear (YC5 and YC6) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement - Rear (See: Seat Cushion Cover and Pad Replacement - Rear) . 3. Remove the seat back hinge bolts from the right and left sides of the cushion frame. 4. Remove the seat cushion frame. Installation Procedure 1. Install the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat back hinge bolts to the right and left sides of the seat cushion frame. Tighten the seat back hinge bolts to the right and left sides of the seat cushion frame 30 N.m (22 lb ft). 3. Install the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement Rear (See: Seat Cushion Cover and Pad Replacement - Rear) . 4. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9107 Seat Cushion Frame Replacement - Rear (YC7) Seat Cushion Frame Replacement - Rear (YC7) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement - Rear (See: Seat Cushion Cover and Pad Replacement - Rear) . Important: Note the position and length of the bolts removed. This will assist with reassembly. 3. Remove the bolts retaining the seat back hinges to the seat cushion frame. Important: Note the position and length of the bolts removed. This will assist with reassembly. 4. Remove the bolts retaining the console to the seat cushion frame. Refer to Center Console Replacement - Rear Seat (See: Interior Moulding / Trim/Console/Service and Repair/Center Console Replacement - Rear Seat) . 5. Remove the seat cushion frame. Installation Procedure 1. Install the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the console to the seat cushion frame in the locations noted during disassembly. Refer to Center Console Replacement Rear Seat (See: Interior Moulding / Trim/Console/Service and Repair/Center Console Replacement - Rear Seat) . Tighten the bolts that retain the console to the seat cushion frame to 30 N.m (22 lb ft). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9108 3. Install the bolts that retain the seat back hinges to the seat cushion frame in the locations noted during disassembly. Tighten the bolts that retain the seat back hinges to the bench seat cushion frame to 30 N.m (22 lb ft). 4. Install the seat cushion cover and pad. 5. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Cushion Cover and Pad Replacement - Rear Seat Cushion Cover and Pad Replacement - Rear Removal Procedure 1. Remove the bench seat and risers from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the right and left sides of the seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Left) . Important: Note the position and length of the bolts you remove. This will assist with reassembly. 3. Remove the bolts retaining the seat back hinges to the seat cushion frame. 4. Remove the J-hooks that retain the seat cushion cover to the seat cushion frame. Important: Note the locations of the hog rings for reassembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9109 5. Remove the hog rings that retain the seat cushion cover to the seat cushion frame located at the rear edge of the seat frame. 6. Remove the seat back cushion cover and pad from the seat cushion frame. Important: Note the locations of the hog rings for reassembly. 7. Remove the hog rings that retain the seat cushion cover to the seat cushion pad located under the seat cushion cover. 8. Remove the seat cushion cover from the seat cushion pad. Installation Procedure 1. Install the seat cushion cover to the seat cushion pad. 2. Install the hog rings that retain the seat cushion cover to the seat cushion pad located under the seat cushion cover. 3. Install the seat back cushion cover and pad to the seat cushion frame. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 9110 4. Install the hog rings that retain the seat cushion cover to the seat cushion frame located at the rear edge of the seat frame. 5. Install the J-hooks that retain the seat cushion cover to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the bolts that retain the seat back hinges to the seat cushion frame. Tighten the bolts that retain the seat back hinges to the seat cushion frame to 30 N.m (22 lb ft). 7. Install the right and left sides of the seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back/Service and Repair/Removal and Replacement/Seat Back Hinge Trim Replacement - Rear Left) . 8. Install the bench seat and risers in the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 9115 Power Door Lock Switch: Diagrams Door Lock Switch - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 9116 Door Lock Switch - Front Passenger Part 1 Door Lock Switch - Front Passenger Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 9117 Power Door Lock Switch: Service and Repair POWER ACCESSORY SWITCH PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the armrest screws and the armrest YC5. 2. Remove the window handle, if equipped. 3. Pull out on the escutcheon in order to remove the lock lever escutcheon. Start with the front edge of the escutcheon. 4. Remove the upper corner trim using the following method: 4.1. Pull the upper corner trim at the top edge. 4.2. Pivot the upper corner trim down in order to clear the tab at the trim panel, YC6 and YC7. 5. Remove the caps that cover the screws for the assist handle. 6. Remove the screws that retain the assist handle to the door. 7. Remove the screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 2. Install the plate to the trim panel. 3. Install the screw at the front edge of the accessory switch mount plate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws at the front edge of the accessory switch mount plate to 5 N.m (44 lb in). 4. Install the assist handle and screws to the door. Tighten Tighten the assist handle screws to 5 N.m (44 lb in). 5. Install the caps that cover the screws on the assist handle. 6. Insert the tab in the slot on the door trim panel. Seat the fastener into the door at the top, YC6 and YC7 in order to install the upper corner trim. 7. Snap the lock lever escutcheon into place in order to install the lock lever escutcheon. Start at the rear edge of the escutcheon. 8. Install the window handle, if equipped. 9. Install the armrest and armrest screws, YC5. Tighten Tighten the armrest screws to 5 N.m (44 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9121 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9122 Outside Rearview Mirror Switch Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Sear - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9126 Seat - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9127 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9128 Seat Adjuster Switch - Driver Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 9131 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. 3. Install the screws that retain the power seat switch to the seat. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 9132 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. Installation Procedure 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 9133 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the power seat switch to the seat. Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Body Wiring - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 9137 Liftglass Lock/Unlock Release Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair Air Dam: Service and Repair Air Intake Baffle Replacement - Radiator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Unhook the power steering cooler lines (2) from the air baffle. 3. Remove the push-in retainers (4) on the right and left sides of the air baffle. 4. Remove the screws (3) that attaches the air baffle to the radiator support. 5. Pull the air baffle rearward in order to release the air baffle from the radiator support. 6. Remove the air baffle (1). Installation Procedure 1. Position the air baffle (1) into the radiator support. 2. Align the tabs of the air baffle to the radiator support before installing the screws. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws (3) that attach the air baffle to the radiator support. Tighten the screws that attaches the air baffle to the radiator support to 2 N.m (18 lb in). 4. Remove the push clips (4) on the right and left sides of the air baffle. 5. Hook the power steering cooler lines (2) to the air baffle. 6. Lower the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside Tailgate Release Handle: Service and Repair Handle and Lock Cylinder - Rear Door Outside Handle and Lock Cylinder - Rear Door Outside New lock cylinders are available as replacement parts. If the door lock cylinders require replacement for any reason, apply a coating of lubricant. Use GM P/N 12346241, Canadian P/N 10953474, or the equivalent, inside the lock case and the cylinder keyway prior to assembling and installing the cylinder. Refer toBinding Lock Cylinders (See: Locks/Door Locks/Service and Repair/Procedures) in Doors in order to repair a binding lock cylinder. Refer to Key and Lock Cylinder Coding in General Information in order to code a new lock cylinder. Removal Procedure 1. Remove the trim panel and the access cover. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Remove the Water Deflector. Refer to Water Deflector Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 3. Use the following procedure in order to remove the control rod from the outside handle: 1. Pry the clip anchor out of the hole. 2. Push the clip away from the lever. 3. Pull the rod (1) and the clip away from the lever. 4. Remove the outside handle nuts. 5. Remove the outside handle. 6. Disconnect the license lamp wiring. 7. Remove the license plate housing bolts. 8. Remove the license plate housing. 9. Remove the door lock shield. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9147 10. Use the following procedure in order to remove the control rod from the lock cylinder (3): 1. Pry the clip anchor out of the hole. 2. Push the clip away from the lever. 3. Pull the rod and the clip away from the lever. 11. Remove the lock cylinder retainer (1). 12. Remove the lock cylinder. Installation Procedure 1. Install the clip to the lock cylinder (3). 2. Install the lock cylinder to the door. 3. Install the lock cylinder retainer (1). 4. Install the control rod to the lock cylinder through the clip. 5. Install the door lock shield. 6. Install the license plate housing. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the license plate housing bolts. Tighten the bolts to 4 N.m (35 lb in). 8. Install the license lamp bolts. Tighten the bolts to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9148 9. Install the clip to the outside handle. 10. Install the outside handle to the door. 11. Install the outside handle nuts. Tighten the nuts to 7 N.m (62 lb in). 12. Install the control rod (1) to the outside handle through the clip. 13. Install the water deflector. Refer to Water Deflector Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 14. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9149 Tailgate Release Handle: Service and Repair Handle Replacement - Lift Gate Handle Replacement - Lift Gate Removal Procedure 1. Remove the screws that retain the liftgate handle. 2. Remove the liftgate handle. Installation Procedure 1. Install the liftgate handle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the liftgate handle. Tighten the screws that retain the liftgate handle to 4 N.m (35 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9150 Tailgate Release Handle: Service and Repair Handle Replacement - Rear Door Inside Handle Replacement - Rear Door Inside Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Remove the water deflector. Refer to Water Deflector Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 3. Remove the control rod (1) from the door lock. 4. Remove the door handle nuts (2). 5. Remove the door handle from the door. Installation Procedure 1. Install the door handle to the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9151 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the door handle nuts (2). Tighten the nuts to 11 N.m (97 lb in). Important: Install new control rod retainers whenever they are removed. 3. Install the control rod to the door handle (1). 4. Install the water deflector. Refer to Water Deflector Replacement See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair 5. Install the door trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Service and Repair Tailgate Striker: Service and Repair Lock Striker Replacement - Upper and Lower Removal Procedure 1. Remove the bolts that retain the striker. 2. Remove the striker from the vehicle. Installation Procedure 1. Install the lock striker to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the lock striker to the vehicle. Tighten the bolts that retain the lock striker to 8 N.m (71 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Disconnect the windshield washer hoses from the windshield wiper arm. 2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 3. Remove the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Remove the air inlet grille panel to cowl screws. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Install the air inlet grille panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the air inlet grille panel to cowl screws. Tighten the air inlet grille panel to cowl screws 2 N.m (18 lb in). 3. Install the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the interior garnish moldings. 2. Use the J 38778 in order to pull the weatherstrip from the pinchweld flange of the door. Start at the upper right corner (6), and pull the weatherstrip down (5,4). Keep pulling the weatherstrip (3) until you reach the top (1) of the door, and have pulled the weatherstrip free. Installation Procedure Important: Ensure that the weatherstrip length is equally distributed around the door opening. 1. Partially attach the weatherstrip to the pinchweld flange in 6 key areas (1,2,3,4,5,6). Important: Fit the weatherstrip to the opening by hand. 2. Seat the weatherstrip onto the pinchweld flange to approximately 154 mm (6 in) on each side of the corner in order to install the weatherstrip at each corner (6,4,3,1). Important: Use a rubber mallet and hit the weatherstrip square to the flange. Otherwise, an undesirable spreading of the carrier will occur that will result in reduced retention. 3. Use a rubber mallet in order to install the weatherstrip into each corner. 4. Use a rubber mallet in order to install the pinchweld flange areas of the hinge and the windshield pillars. 5. Ensure that the following conditions are met: * The weatherstrip fits into the corner and matches the radius of the pinchweld flange. * The weatherstrip is seated completely onto the flange in all areas, resulting in a smooth vinyl-trim around the entire door opening. * There is not any distortion or excess spreading of the carrier as a result of hitting the carrier improperly with the rubber mallet. * The weatherstrip is not kinked or distorted after installation. * The weatherstrip is lubricated with GM weatherstrip silicone lube. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Page 9164 * Install the interior garnish moldings. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Upper Removal Procedure 1. Pull the molding (1) from the molding flange. 2. Remove the molding (1). Installation Procedure 1. Install the molding (1). 2. Push the molding (1) onto the flange. Start at the pre-formed corners. Work toward the straight flanges. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the rear hood seal retainers by using J 38778 . 2. Remove the rear hood seal from the hood. Installation Procedure 1. Install the rear hood seal to the hood. 2. Push the retainers into the hood in order to retain the rear hood seal. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Quarter Window Glass Weatherstrip > Component Information > Service and Repair Quarter Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Swing Out Window Removal Procedure 1. Open the swing out window. 2. Pull the weatherstrip from the pinch weld flange. 3. Grasp the weatherstrip at the lower corner and pull up and away from the pinch-weld. Installation Procedure 1. Install the weatherstrip to the pinch-weld flange. 2. Put the weatherstrip on the pinch-weld flange and push downward until fully seated. 3. Close the swing out window. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Outer Belt Sealing Strip Replacement - Outer Belt Removal Procedure 1. Roll the window down. 2. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 3. Remove the outer sealing strip from the door frame. Installation Procedure 1. Install the outer sealing strip to the door frame. 2. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9178 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (Cargo Doors) Weatherstrip Replacement - Rear Door (Cargo Doors) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers (2). 2. Use the 3M Release Agent or an equivalent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic weather retainers (3). 4. Remove the weatherstrip (1) from the left door. 5. Remove the weatherstrip from the right door. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip to the right door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9179 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip (3) to the left door. 3. Install the plastic retainers (2) into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9180 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (E54) Weatherstrip Replacement - Rear Door (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers. 2. Use 3M Release Agent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic retainers. 4. Remove the left door weatherstrip. 5. Remove the right door weatherstrip. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the right door weatherstrip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9181 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the left door weatherstrip. 3. Install the plastic retainers into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the door. 2. Remove the fourth pillar trim. Refer to Trim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) and Trim Replacement - Fourth Pillar Right (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Right) in Interior Trim. 3. Remove the rear upper garnish molding. Refer to Garnish Molding Replacement - Rear Upper (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) in Interior Trim. 4. Remove the body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) and Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) in Interior Trim. 5. Remove the rear trim plate. Refer to Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Carpet Retainer Replacement) in Interior Trim. 6. Pull the weatherstrip from the pinch-weld flange. Start at the upper right corner. Installation Procedure Important: The weatherstrip attaches to the pinch-weld flange in 6 areas. The weatherstrip length distributes equally around the door opening. 1. Install the weatherstrip at the top right corner. Seat the weatherstrip onto the pinch-weld flange. 2. Position and install the weatherstrip by hand. 3. Using a rubber mallet during the final installation may be required in the thick flange areas and in each corner. 4. Install the rear trim plate. Refer to Carpet Retainer Replacement (See: Interior Moulding / Trim/Carpet/Service and Repair/Carpet Retainer Replacement) in Interior Trim. 5. Install the body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) and Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) in Interior Trim. 6. Install the rear upper garnish molding. Refer to Garnish Molding Replacement - Rear Upper (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) in Interior Trim. 7. Install the fourth pillar trim. Refer to Trim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) and Trim Replacement - Fourth Pillar Right (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Right) in Interior Trim. 8. Close the door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 9189 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 9190 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 9191 Cruise Control Module (CCM) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 9192 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove cruise control cable from throttle body lever. 2. Remove the cruise control cable bead (2) from the end of the ribbon (1). IMPORTANT: Do not allow the cruise control ribbon to retract into the module assembly 3. Disconnect the electrical connector from cruise module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 9193 4. Remove the cruise control module bolts. 5. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module. 2. Install the cruise control module bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the cruise control module bolts to 12 N.m (106 lb in). 3. Connect the electrical connector to cruise module. 4. Install cruise control cable bead (2) to ribbon (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 9194 5. Install cruise control cable to throttle body lever. 6. Perform the functional check. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair CRUISE CONTROL CABLE REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Remove the engine cover. 3. Do not remove the C-clip from the cruise control end connector. NOTE: Do not remove the C-clip from the cruise control connector. The C-clip was not designed for removal. Damage may occur when removing. 4. Do not remove the adjuster screw from the end of the cruise control cable. Adjustments will not be needed. 5. Remove the cruise control cable from the throttle linkage, using a suitable tool in order to lightly pry off the end of the cruise control cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9198 6. Disconnect the cruise control cable from the throttle linkage. 7. Disconnect the cruise control cable from the cable bracket (1). 8. Remove the screw that retains the cruise control cable to the HVAC module (2). 9. Remove the cruise control cable from the cruise control module housing. 10. Disconnect the cruise control cable bead (2) from the end of the ribbon (1). IMPORTANT: Do not allow the cruise control ribbon to retract into the module assembly. 11. Remove the cruise control cable from the vehicle. INSTALLATION PROCEDURE 1. Install the cruise control cable to the vehicle. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9199 2. Remove all bends and twists from the cruise control module ribbon and cable by rotating until removed. 3. Attach the cruise control cable bead (2) to the cruise control module ribbon (1). IMPORTANT: - Do not twist the cruise control module ribbon (1). - Pull the cruise control cable (2) in order to verify retention to the ribbon (1). 1. Inspect the orientation of the cruise control ribbon buckle to the cable end fitting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9200 2. Install the cruise control cable to the cable bracket (1). 3. Install the screw that retains the cruise control cable to the HVAC module (2). 4. Install the cruise control cable to the cruise control module housing. 5. Connect the cruise control cable to the throttle linkage. 6. Snap the cruise control cable fitting (3) into the cruise control module (4). 7. In order to install a new cruise control cable, pull the cruise control cable ferrule through the opposite end of the fitting.The ferrule color is natural and must be visible when pulled through the fitting. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9201 8. From inside the vehicle, snap the cable fitting onto the stud on the throttle body linkage. 9. Reroute and insert the cruise control cable fitting into the round hole in the accelerator bracket. IMPORTANT: Verify that the cable fitting locking tabs are expanded, and that the tabs are locked in the accelerator bracket hole. 10. When installing a new cruise control cable or adjusting an old cruise control cable (3), engage the lock (1) on the cruise control adjuster (2). The white paint mark will disappear when the adjuster is locked. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. 11. Install the cruise control cable to the HVAC module by placing the cable inside the module clip and snapping the clip closed. 12. Perform the Cruise Control System Functional Test. Refer to Cruise Control Inoperative/Malfunctioning. 13. If the cruise control cable (3) requires adjustment, release the lock on the cable adjuster (2) using the following steps: 13.1. Gently squeeze the tabs on the adjuster plunger (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9202 13.2. Pull upward on the adjuster plunger (1). 13.3. Rotate the black plastic screw on the cruise control cable end that connects to the throttle body until the proper lash is achieved. SPECIFICATION The lash should be within 0.0-0.6 mm (0.0-0.024 in). 14. After completing the adjustment, reset the lock. 15. Install the engine cover. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 9210 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 9211 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 9212 Cruise Control Module (CCM) Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 9213 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove cruise control cable from throttle body lever. 2. Remove the cruise control cable bead (2) from the end of the ribbon (1). IMPORTANT: Do not allow the cruise control ribbon to retract into the module assembly 3. Disconnect the electrical connector from cruise module. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 9214 4. Remove the cruise control module bolts. 5. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module. 2. Install the cruise control module bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the cruise control module bolts to 12 N.m (106 lb in). 3. Connect the electrical connector to cruise module. 4. Install cruise control cable bead (2) to ribbon (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 9215 5. Install cruise control cable to throttle body lever. 6. Perform the functional check. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: - The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. - The IPC performs the bulb check. - The IPC detects a loss of class 2 communications with the EBCM. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9228 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9229 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9230 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9231 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9232 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9233 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9234 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9235 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9236 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9237 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9238 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9239 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9240 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9241 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9242 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9243 Audible Warning Device: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9244 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9245 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9246 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9247 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9248 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9249 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9250 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9251 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9252 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9253 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9254 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9255 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9256 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9257 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9258 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9259 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9260 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9261 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9262 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9263 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9264 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9265 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9266 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9267 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9268 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9269 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9274 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9275 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9288 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9289 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9290 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9291 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9292 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9293 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9294 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9295 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9296 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9301 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9302 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9303 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9304 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Audible Warning Device: Electrical Diagrams Audible Warnings Diagram 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9313 Audible Warnings Diagram 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 9314 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The BCM generates the audible warnings through an internal speaker. The BCM emits audible warnings based on various inputs. If the BCM receives multiple audible warning requests, the warning with the highest priority sounds first. Fasten Safety Belt Warning The BCM activates the fasten safety belt audible warning, and also sends a class 2 message to the IPC to illuminate the fasten safety belt indicator when the following occurs: The ignition switch transitions to RUN. - The seat belt is not buckled and the signal circuit is low. If the seat belt is buckled while the chime is sounding, the chime stops. If the seat belt is unbuckled after the initial transition to RUN, the chime does not sound. Key-In-Ignition Warning The BCM activates the key-in-ignition audible warning when all of the following occurs: The driver door is open and the signal circuit is low. - The key is in the ignition and the signal circuit is low. The audible warning will sound for as long as the above conditions exist. Lights On Warning The BCM activates the lights on warning when the following occurs: The ignition is not in the RUN or START position. - The headlamp switch is in the PARK or Head position. - The instrument panel dimmer switch is not at the most dim setting. The audible warning will sound for as long as the above conditions exist. Low Fuel Warning The BCM activates the low fuel warning when the following occurs: The ignition is in the RUN or START position. - The fuel level is below 17 percent. - The BCM receives a class 2 message from the PCM requesting an audible warning. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair Audible Warning Device Control Module: Service and Repair MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the multifunction alarm assembly from the convenience center located under the left side of the instrument panel. 2. Release the single tab connector on the top of the assembly. 3. Pull out the single tab connector. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly to the convenience center. 2. Align the retaining tab. 3. Press the tab in place Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9322 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9323 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9324 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9325 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9326 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9327 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9328 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9329 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9330 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9331 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9332 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9333 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9334 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9335 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9336 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9337 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9338 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9339 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9340 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9341 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9342 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9343 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9344 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9345 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9346 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9347 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9348 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9366 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9367 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9368 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9369 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9370 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9371 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9372 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9373 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9374 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9375 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9376 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9377 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9378 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9379 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9380 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9381 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9382 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9383 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9384 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9385 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9386 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9387 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9388 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9389 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9390 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9391 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9392 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9393 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9394 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9395 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9396 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9397 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9398 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9399 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9400 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9401 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9402 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 Brake Warning Indicator: Electrical Diagrams Brake Warning System Diagram Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Page 9407 Brake Warning Indicator: Description and Operation Brake Warning System Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: - The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. - The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. - The EBCM detects an ABS malfunction which disables Dynamic Rear Proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. - The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. - The IPC detects a loss of class 2 communications with the BCM or with the EBCM. Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when the following occurs: - The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. - The EBCM detects a low brake fluid condition and sends a class 2 message to the IPC. - The IPC performs the bulb check. - An ABS-disabling malfunction also disables Dynamic Rear Proportioning (DRP). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9412 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9413 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9414 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9415 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9416 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9417 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9418 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9419 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9420 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9421 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9422 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9423 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9424 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9425 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9426 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9427 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9428 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9429 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9430 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9431 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9432 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9433 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9434 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9435 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9436 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9437 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9438 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9439 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9440 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9441 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9442 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9443 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9444 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9445 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9446 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9447 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9448 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9449 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9450 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9451 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9452 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9453 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9454 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9455 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9456 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9457 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9458 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9459 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9460 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9461 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9462 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9463 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9464 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9465 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9466 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9467 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9468 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9469 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9470 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9471 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9472 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9473 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9474 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9475 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9476 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9477 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9478 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9479 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9480 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9481 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9482 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9483 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9484 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9485 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9486 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9493 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9494 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9495 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9496 Cigar Lighter Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9497 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Schematics Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair Compass: Service and Repair ELECTRONIC COMPASS CALIBRATION COMPASS CALIBRATION 1. Turn ON the ignition. IMPORTANT: Before calibrating the compass, drive the vehicle to a area that is magnetically clean, and free of large metallic objects. 2. Press the MODE button in order to advance to the COMP/TEMP mode. 3. Simultaneously depress and hold the US/MET and MODE buttons until a C is displayed, in approximately 10 seconds. 4. Release both buttons. 5. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the C is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT 1. Locate your geographic location. IMPORTANT: Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. 2. Turn ON the ignition, with the engine OFF. 3. Press the MODE button in order to advance to the COMP/TEMP mode. 4. With the DIC in the COMP/TEMP mode, simultaneously depress and hold the MODE and US/MET buttons until VAR CAL is displayed, in approximately 5 seconds. 5. Release both buttons. 6. Press the US/MET button in order to advance to the proper zone number. 7. Press the MODE button in order to enter and set the zone number. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9506 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor connector (1) located on the frame crossmember. 7. Disconnect the inflatable restraint front end discriminating sensor connector. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9507 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9508 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 7. Disconnect the I/P module yellow 2-way connector (1). Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9509 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9510 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connector to the inflatable restraint front end discriminating sensor (1) located on the frame crossmember. 2. Install the CPA to the inflatable restraint front end discriminating sensor connector. 3. Install the AIR BAG fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9511 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6 Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9512 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the passenger knee bolster. 5. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9513 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the passenger knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Headlamp and Panel Dimmer Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 9520 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 9521 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 9522 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 9523 Left Kick Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 9524 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 9525 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 9528 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9535 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9536 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9537 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9538 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9539 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9540 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9541 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9542 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9543 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9544 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9545 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9546 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9547 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9548 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9549 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9550 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9551 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9552 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9553 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9554 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9555 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9556 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9557 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9558 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9559 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9560 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9561 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9562 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9563 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9564 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9565 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9566 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9567 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9568 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9569 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9570 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9571 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9572 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9573 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9574 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9575 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9576 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9577 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9578 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9579 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9580 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9581 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9582 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9583 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9584 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9585 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9586 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9587 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9588 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9589 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9590 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9591 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9592 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9593 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9594 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9595 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9596 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9597 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9598 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9599 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9600 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9601 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9602 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9603 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9604 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9605 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9606 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9607 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9608 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9609 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9610 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9611 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9612 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9613 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9614 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9615 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9616 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9617 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9618 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9619 Driver Information Center (DIC) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9620 Driver/Vehicle Information Display: Electrical Diagrams Driver Information System Diagram Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 9621 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION The driver information center (DIC) consists of a multi-function electronic display placed in the overhead console. The DIC displays the following information: - The vehicle fuel information - The outside temperature - The direction the vehicle is facing The display parameters are cycled, changed, and acknowledged using the following 2 DIC buttons mounted at the side of the driver information center: US/MET: Allows the display to switch between English and Metric units. MODE: Used to toggle between OFF, COMP/TEMP and TRIP. COMP/TEMP COMP: In the Compass Mode, one of eight compass readings (N, NE, E, SE, S, SW, W, and NW) will be displayed to indicate the direction the vehicle is facing. TEMP: In the Temperature Mode, the outside air temperature is displayed in either °C or °F. If the outside air temperature is below 3°C (37°F), the display will toggle between ICE and the current outside air temperature in 8 second increments. TRIP In the Trip Mode, the DIC displays the following information based on class 2 serial data: AVG ECON The DIC displays the average fuel economy since the last reset. AVG SPEED: The DIC displays the average speed since the last reset. FUEL USED: The DIC displays the amount of fuel used since the last reset. INST ECON: The DIC displays the instantaneous fuel economy since the last second of driving. RANGE: The DIC displays the estimated distance that can be travelled with the remaining fuel in the tank, based on the fuel economy for the last few hours of driving. The display format for each mode is indicated in the table. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 9622 Driver/Vehicle Information Display: Service and Repair DRIVER INFORMATION CENTER MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the overhead console (3). 2. Remove the display lens and the switch plate (1). 3. Disconnect the electrical connectors. 4. Remove the temperature/compass electronic display module (2). INSTALLATION PROCEDURE 1. Install the temperature/compass electronic display module (2). 2. Connect the electrical connectors. 3. Install the display lens and the switch plate (1). 4. Install the overhead console (3). 5. Recalibrate the compass. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 9626 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 9627 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9633 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor connector (1) located on the frame crossmember. 7. Disconnect the inflatable restraint front end discriminating sensor connector. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9634 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9635 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 7. Disconnect the I/P module yellow 2-way connector (1). Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the passenger knee bolster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9636 5. Remove the AIR BAG fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the AIR BAG fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9637 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connector to the inflatable restraint front end discriminating sensor (1) located on the frame crossmember. 2. Install the CPA to the inflatable restraint front end discriminating sensor connector. 3. Install the AIR BAG fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9638 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6 Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9639 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the passenger knee bolster. 5. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9640 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the AIR BAG fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the passenger knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations > Page 9644 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations > Page 9645 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations > Page 9646 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the symbols shown when commanded ON. The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 9654 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 9655 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 9656 Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Page 9657 Odometer: Description and Operation ODOMETER The IPC contains a season odometer and a trip odometer. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC displays the vehicle mileage and the trip mileage as determined by the IPC. The IPC calculates the mileage based on the vehicle speed signal from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Position (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9664 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Camshaft Postion (CMP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9665 Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Left Front Interior Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9669 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9670 Notice: Refer to Fastener Notice in Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair Audible Warning Device Control Module: Service and Repair MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the multifunction alarm assembly from the convenience center located under the left side of the instrument panel. 2. Release the single tab connector on the top of the assembly. 3. Pull out the single tab connector. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly to the convenience center. 2. Align the retaining tab. 3. Press the tab in place Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Headlamp and Panel Dimmer Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 9682 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 9683 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 9684 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 9685 Left Kick Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 9686 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 9687 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 9690 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 9694 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 9695 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 9699 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 9700 Tilt Column Shift Steering Column Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 9701 Tilt Column Shift Steering Column Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Left Front Interior Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9705 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Disconnect the electrical connector. 2. Remove the park brake warning lamp switch mounting bolt. 3. Remove the park brake warning lamp switch. Installation Procedure 1. Install the park brake warning lamp switch. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9706 Notice: Refer to Fastener Notice in Service Precautions. See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the park brake lamp switch mounting bolt. Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SPEEDOMETER The IPC displays the vehicle speed based on the information from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit (4000 pulses/mile) from the PCM in order to calculate the vehicle speed. If the IPC detects a malfunction in the vehicle speed signal circuit, the IPC uses the class 2 message from the PCM indicating the vehicle speed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER The IPC displays the engine speed based on the information from the PCM. The PCM converts the data from the engine speed sensor to a 2 pulses/engine revolution signal. The IPC uses the engine speed signal circuit (2 pulses/engine revolution) from the PCM in order to calculate the engine speed. If the IPC detects a malfunction in the engine speed signal circuit, the IPC uses the class 2 message from the PCM indicating the engine speed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9730 Ambient Light Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9731 Ambient Light Sensor: Service and Repair DAYTIME RUNNING LAMPS (DRL) AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Lift upward on the center defogger grille located in center of the dash to expose the DRL photo sensor (1) retainer. 2. Turn the DRL photo sensor counterclockwise 1/4 turn in order to remove. 3. Disconnect the electrical connection from the DRL photo sensor (1). INSTALLATION PROCEDURE 1. Connect the electrical connection to the DRL photo sensor (1). 2. Insert the DRL photo sensor (1) and turn counterclockwise 1/4 turn in order to seat. 3. Install the defogger grille located in the center of the dash by push downward. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Backup Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 9736 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Connector Views Backup Lamp: Connector Views Backup Lamp - Left Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Connector Views > Page 9739 Backup Lamp - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Page 9740 Backup Lamp: Description and Operation BACKUP LAMPS The TURN-B/U fuse in the IP fuse block supplies battery positive voltage to the normally open backup lamp switch. When driver places the gear selector lever is in the REVERSE position, the backup lamp switch closes and the current flow is from the backup lamp switch to the backup lamps. The backup lamps are grounded at G400 and G401. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 9745 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 9746 Brake Lamp: Description and Operation STOPLAMPS The STOP/HAZ fuse in the IP fuse block supplies battery positive voltage to the normally open stoplamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to the multifunction turn signal switch. The current flow is now to the stoplamps which are grounded at G400 and G401. The center high mounted stoplamp (CHMSL) is grounded at G400. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Stop Lamp Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9750 Brake Light Switch: Diagrams Stop Lamp Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9751 Tail/Stop and Turn Signal Lamp - Left Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9752 Tail/Stop and Turn Signal Lamp - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9753 Tail/Stop Lamp - Left - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9754 Tail/Stop Lamp - Right - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9755 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the battery negative cable. 2. Remove the retainer (3) from the brake pedal pin. 3. Unsnap the switch (2) and pushrod (4) from the brake pedal (1) pin. 4. Disconnect the electrical connector. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9756 1. Connect the electrical connector. 2. Install the switch (2) and pushrod (4) onto the brake pedal (1) pin. 3. Install the retainer (3) onto the brake pedal (1) pin. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center High Mounted Stop Lamp (CHMSL) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 9760 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the center high-mounted stop lamp retaining screws. 2. Gently pull the electrical connector through the top of the roof. 3. Disconnect the electrical connector. 4. Remove the high-mounted stop lamp from the vehicle. INSTALLATION PROCEDURE 1. Install the high-mounted stop lamp to the vehicle. 2. Connect the electrical connector. 3. Carefully push the electrical connector back into the roof. 4. Install the high-mounted stop lamp retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams I/P Compartment Lamp Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 9765 Glove Box Lamp: Description and Operation IP COMPARTMENT LAMP The inadvertent power relay also provides battery positive voltage to the instrument panel compartment lamp. When the IP compartment is opened, the internal switch closes to provide a ground circuit and the IP compartment lamp illuminates. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Instrument Panel (I/P) Lamp Replacement Glove Box Lamp: Service and Repair Instrument Panel (I/P) Lamp Replacement INSTRUMENT PANEL (I/P) LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster. 2. Remove the socket and bulb assembly from the back of the cluster. IMPORTANT: Bulbs and sockets are one-piece units and should not be separated. INSTALLATION PROCEDURE 1. Install the socket and bulb assembly to the back of the cluster. 2. Install the instrument cluster. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Instrument Panel (I/P) Lamp Replacement > Page 9768 Glove Box Lamp: Service and Repair Instrument Panel (I/P) Storage Compartment Lamp Replacement INSTRUMENT PANEL (I/P) STORAGE COMPARTMENT LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the instrument panel storage compartment. 2. Gently depress the tabs at the top and the bottom of the compartment lamp switch by using a small flat-bladed tool. 3. Remove the compartment lamp switch. 4. Disconnect the electrical connector from the switch. 5. Pull the bulb from the compartment lamp switch. INSTALLATION PROCEDURE 1. Install the bulb to the compartment lamp switch. 2. Connect the electrical connector to the switch. 3. Install the compartment lamp switch and press in order to engage the tabs. 4. Close the instrument panel storage compartment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Service and Repair Daytime Running Lamp Diode Assembly: Service and Repair DAYTIME RUNNING LAMPS (DRL) DIODE REPLACEMENT REMOVAL PROCEDURE 1. Remove the body side front lower trim panel. 2. Remove the screw that retains the diode to the body lock pillar. 3. Disconnect the electrical connector from the diode. 4. Remove the diode from the vehicle. INSTALLATION PROCEDURE 1. Install the diode to the vehicle. 2. Connect the electrical connector to the diode. 3. Install the screw that retains the diode to the body lock pillar. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw that retains the diode to the body lock pillar to 6 N.m (53 lb in). 4. Install the body side front lower trim panel. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Headlamp and Panel Dimmer Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair DOME AND READING LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Release the tab on one end of the lens. 2. Remove the lens by swinging the lens downward. 3. Remove the bulb from the assembly by pulling the bulb straight down. INSTALLATION PROCEDURE 1. Push the bulb up into the contacts/retainers. 2. Align the tabs in the lens with the slots in the assembly. 3. Push the lens into place. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Switch > Component Information > Locations Dome Lamp Defeat Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 9786 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 9787 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 9788 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 9789 Left Kick Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 9790 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 9791 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 9794 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 9799 Fuse Block - I/P Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 9800 Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Open the driver door. 2. In order to remove the flasher module (1) from the instrument panel (IP) convenience center, simultaneously perform the following: 2.1. Lift upward on the tab that retains the flasher module to the IP convenience center. 2.2. Remove the flasher module from the IP convenience center. INSTALLATION PROCEDURE 1. Position the flasher module (1) to the IP convenience center. 2. Engage the flasher module until fully seated and the retaining tab clicks. 3. Close the driver door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 9805 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 9806 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 9807 Instrument Panel Cluster (IPC) Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 9808 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 9809 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the instrument panel cluster trim plate. 3. Remove the switch from the plate by using the following procedure: 3.1. Release the retaining tabs on the sides of the switch. 3.2. Pull the switch out of the plate. 3.3. Disconnect the electrical connector(s) at the back of the headlamp switch. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the back of the switch. 2. Install the headlamp switch to the plate by snapping the switch into place. 3. Install the instrument panel cluster trim plate. 4. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9821 Fuse Block - I/P Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation Interior Lighting Module: Description and Operation INTERIOR LAMPS The interior lighting consist of the following three groups. This first group includes lamps that may not be dimmed. The courtesy lamps - The stepwell lamps - The dome/reading lamps - The vanity mirror lamps - The IP compartment lamps - The driver and passenger door control switch illumination - The Rear Audio Control Illumination Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views License Lamp Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9832 License Plate Lamp: Description and Operation PARK, TAIL, MARKER AND LICENSE LAMPS The park, tail, marker and license lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PK LPS fuse in the IP fuse block supplies battery positive voltage to the park lamp relay and the headlamp switch. The body control module (BCM) provides a ground, or control circuit, to the park lamp relay coil circuit during ALC operation. When the park lamps are turned on during ALC, the BCM energizes the park lamp relay. The park lamps can also be supplied battery positive voltage directly from the headlamp switch. Current flow is to the park, tail, marker and license lamps. The front park and marker lamps are grounded at G100 and G101. The rear park, tail, marker and license lamps are grounded at G400 and G401. If the headlight switch is left in the ON position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9833 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Remove the screws from the license lamp. 3. Remove the bulb. INSTALLATION PROCEDURE 1. Install the bulb. 2. Install the license lamp. 3. Install the license lamp screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the license lamp screws to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair DOME AND READING LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Release the tab on one end of the lens. 2. Remove the lens by swinging the lens downward. 3. Remove the bulb from the assembly by pulling the bulb straight down. INSTALLATION PROCEDURE 1. Push the bulb up into the contacts/retainers. 2. Align the tabs in the lens with the slots in the assembly. 3. Push the lens into place. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Connector Views Marker Lamp: Connector Views Marker Lamp - LF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Connector Views > Page 9842 Marker Lamp - LR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Connector Views > Page 9843 Marker Lamp - RF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Connector Views > Page 9844 Marker Lamp - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Connector Views > Page 9845 Stepwell Lamp Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 9846 Marker Lamp: Description and Operation PARK, TAIL, MARKER AND LICENSE LAMPS The park, tail, marker and license lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PK LPS fuse in the IP fuse block supplies battery positive voltage to the park lamp relay and the headlamp switch. The body control module (BCM) provides a ground, or control circuit, to the park lamp relay coil circuit during ALC operation. When the park lamps are turned on during ALC, the BCM energizes the park lamp relay. The park lamps can also be supplied battery positive voltage directly from the headlamp switch. Current flow is to the park, tail, marker and license lamps. The front park and marker lamps are grounded at G100 and G101. The rear park, tail, marker and license lamps are grounded at G400 and G401. If the headlight switch is left in the ON position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 9847 Marker Lamp: Service and Repair STEPWELL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the screw that retains the lens. 2. Gently pry off the lens. 3. Pull out the bulb. INSTALLATION PROCEDURE 1. Install the bulb. 2. Install the lens to the body with the screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the stepwell lamp body screw to 2 N.m (18 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 9852 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views Parking Lamp: Connector Views Park/Turn Signal Lamp - LF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views > Page 9855 Park/Turn Signal Lamp - LF - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views > Page 9856 Park/Turn Signal Lamp - RF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views > Page 9857 Park/Turn Signal Lamp - RF - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 9858 Parking Lamp: Description and Operation PARK, TAIL, MARKER AND LICENSE LAMPS The park, tail, marker and license lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PK LPS fuse in the IP fuse block supplies battery positive voltage to the park lamp relay and the headlamp switch. The body control module (BCM) provides a ground, or control circuit, to the park lamp relay coil circuit during ALC operation. When the park lamps are turned on during ALC, the BCM energizes the park lamp relay. The park lamps can also be supplied battery positive voltage directly from the headlamp switch. Current flow is to the park, tail, marker and license lamps. The front park and marker lamps are grounded at G100 and G101. The rear park, tail, marker and license lamps are grounded at G400 and G401. If the headlight switch is left in the ON position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 9859 Parking Lamp: Service and Repair PARK/TURN SIGNAL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Remove the mounting screws. 3. Remove the park/turn signal lamp from the vehicle. 4. Remove the lamp sockets from the park/turn signal lamp housing. 5. Remove the bulbs from the lamp sockets. INSTALLATION PROCEDURE 1. Install the bulbs into the lamp sockets. 2. Install the lamp socket to the park/turn signal lamp housing. 3. Install the park/turn signal lamp to the vehicle. 4. Install the mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the mounting screws to 1.4 N.m (12 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 9864 Fuse Block - I/P Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation Interior Lighting Module: Description and Operation INTERIOR LAMPS The interior lighting consist of the following three groups. This first group includes lamps that may not be dimmed. The courtesy lamps - The stepwell lamps - The dome/reading lamps - The vanity mirror lamps - The IP compartment lamps - The driver and passenger door control switch illumination - The Rear Audio Control Illumination Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9872 Ambient Light Sensor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9873 Ambient Light Sensor: Service and Repair DAYTIME RUNNING LAMPS (DRL) AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Lift upward on the center defogger grille located in center of the dash to expose the DRL photo sensor (1) retainer. 2. Turn the DRL photo sensor counterclockwise 1/4 turn in order to remove. 3. Disconnect the electrical connection from the DRL photo sensor (1). INSTALLATION PROCEDURE 1. Connect the electrical connection to the DRL photo sensor (1). 2. Insert the DRL photo sensor (1) and turn counterclockwise 1/4 turn in order to seat. 3. Install the defogger grille located in the center of the dash by push downward. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Stop Lamp Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9877 Brake Light Switch: Diagrams Stop Lamp Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9878 Tail/Stop and Turn Signal Lamp - Left Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9879 Tail/Stop and Turn Signal Lamp - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9880 Tail/Stop Lamp - Left - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9881 Tail/Stop Lamp - Right - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9882 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the battery negative cable. 2. Remove the retainer (3) from the brake pedal pin. 3. Unsnap the switch (2) and pushrod (4) from the brake pedal (1) pin. 4. Disconnect the electrical connector. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9883 1. Connect the electrical connector. 2. Install the switch (2) and pushrod (4) onto the brake pedal (1) pin. 3. Install the retainer (3) onto the brake pedal (1) pin. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Locations Dome Lamp Defeat Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 9890 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 9891 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 9892 I/P Wiring To Front Passenger Door Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 9893 Left Kick Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 9894 Side Door Contact Plate And Side Door Jamb Switch Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 9895 Door Location View - RR Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 9898 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. 3. Tighten the nut on the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Instrument Cluster Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9902 Instrument Cluster Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9903 Instrument Panel Cluster (IPC) Wiring Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9904 Instrument Panel Cluster (IPC) Wiring Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9905 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9906 Instrument Cluster Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the instrument panel cluster trim plate. 3. Remove the switch from the plate by using the following procedure: 3.1. Release the retaining tabs on the sides of the switch. 3.2. Pull the switch out of the plate. 3.3. Disconnect the electrical connector(s) at the back of the headlamp switch. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the back of the switch. 2. Install the headlamp switch to the plate by snapping the switch into place. 3. Install the instrument panel cluster trim plate. 4. Connect the battery negative cable. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 9920 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views Tail Lamp: Connector Views Tail/Stop and Turn Signal Lamp - Left Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 9923 Tail/Stop and Turn Signal Lamp - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 9924 Tail/Stop Lamp - Left - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 9925 Tail/Stop Lamp - Right - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 9926 Tail Lamp: Description and Operation PARK, TAIL, MARKER AND LICENSE LAMPS The park, tail, marker and license lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PK LPS fuse in the IP fuse block supplies battery positive voltage to the park lamp relay and the headlamp switch. The body control module (BCM) provides a ground, or control circuit, to the park lamp relay coil circuit during ALC operation. When the park lamps are turned on during ALC, the BCM energizes the park lamp relay. The park lamps can also be supplied battery positive voltage directly from the headlamp switch. Current flow is to the park, tail, marker and license lamps. The front park and marker lamps are grounded at G100 and G101. The rear park, tail, marker and license lamps are grounded at G400 and G401. If the headlight switch is left in the ON position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 9927 Tail Lamp: Service and Repair TAIL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Open the rear doors. 3. Remove the screws that retain the tail lamp to the body. 4. Remove the lamp sockets from the back of the tail lamp by using the following procedure: 4.1. Squeeze the tang at the electrical connector. 4.2. Turn the bulb and the base. 5. Remove the bulbs from the sockets. IMPORTANT: Do not remove the grease from the socket. INSTALLATION PROCEDURE 1. Apply a light coating of lithium grease to the sockets if there is no grease in the sockets. 2. Install the bulbs into the sockets. 3. Install the lamp sockets to the back of the tail lamp. 4. Install the tail lamp to the body. 5. Install the screws to retain the tail lamp to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the tail lamp screws to 3 N.m (27 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Fuse Block - I/P Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 9932 Fuse Block - I/P Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 9933 Turn Signal Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Open the driver door. 2. In order to remove the flasher module (1) from the instrument panel (IP) convenience center, simultaneously perform the following: 2.1. Lift upward on the tab that retains the flasher module to the IP convenience center. 2.2. Remove the flasher module from the IP convenience center. INSTALLATION PROCEDURE 1. Position the flasher module (1) to the IP convenience center. 2. Engage the flasher module until fully seated and the retaining tab clicks. 3. Close the driver door. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 9938 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9939 Turn Signal Lamp: Diagrams Park/Turn Signal Lamp - LF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9940 Park/Turn Signal Lamp - LF - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9941 Park/Turn Signal Lamp - RF Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9942 Park/Turn Signal Lamp - RF - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9943 Tail/Stop and Turn Signal Lamp - Left Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9944 Tail/Stop and Turn Signal Lamp - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9945 Turn Signal Lamp - LR - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9946 Turn Signal Lamp - RR - Export Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9947 Turn Signal Lamp: Description and Operation TURN SIGNAL LAMPS The STOP/HAZ fuse in the IP fuse block supplies battery positive voltage to the multifunction hazard switch assembly. The TURN-B/U fuse in the IP fuse block supplies Ignition positive voltage to the multifunction turn signal switch assembly. With the ignition switch in the RUN or START position, ignition positive voltage is connected through the multifunction turn signal and hazard switch assembly to the flasher module which is grounded at G105. When the turn signal switch is placed in either the left or right position, the circuit is complete from the flasher module to the turn signal lamps and to ground. The flasher module then sends an on-off voltage signal to either the left or right turn signals and their instrument panel cluster (IPC) indicator. When the hazard switch is activated, all turn signal lamps will flash including both IPC turn indicators. The front turn signals are grounded at G101 and G100. The rear turn signals are grounded at G400 and G401. On the export vehicle, the rear turn signal lamps are separate amber lamps utilizing single filament bulbs grounded at G400 and G401. There are also amber side repeater lamps on each fender which are grounded at G101 and G100. The front side marker lamps stay on steady and do not flash alternately with the turn signals as the domestic vehicle does due to they are grounded directly to G101 and G100. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 9948 Turn Signal Lamp: Service and Repair PARK/TURN SIGNAL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Remove the mounting screws. 3. Remove the park/turn signal lamp from the vehicle. 4. Remove the lamp sockets from the park/turn signal lamp housing. 5. Remove the bulbs from the lamp sockets. INSTALLATION PROCEDURE 1. Install the bulbs into the lamp sockets. 2. Install the lamp socket to the park/turn signal lamp housing. 3. Install the park/turn signal lamp to the vehicle. 4. Install the mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the mounting screws to 1.4 N.m (12 lb in). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Connector Views Vanity Lamp: Connector Views Vanity Mirror Lamp - Left Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Connector Views > Page 9956 Vanity Mirror Lamp - Right Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 9957 Vanity Lamp: Description and Operation VANITY LAMPS The inadvertent power relay also provides battery positive voltage to each vanity mirror lamp. When the vanity mirror cover on the sunshade is opened, the internal switch closes to provide a ground circuit and the vanity lamp illuminates. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 9958 Vanity Lamp: Service and Repair VANITY MIRROR LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn the sunshade down. 2. Lift the vanity mirror cover. 3. Remove the lens by gently prying at the top or the bottom of the lens with a suitable flat bladed tool. 4. Lift the bulb(s) straight out. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 9959 1. Press the bulb(s) in. 2. Install the lens. 3. Close the vanity mirror cover. 4. Turn the sunshade up. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 9969 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 9970 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 9971 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 9977 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 9978 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 9979 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Page 9980 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Page 9981 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9984 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9985 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9986 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9987 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9988 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9989 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9990 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9991 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9992 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9993 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9994 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9995 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9996 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9997 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9998 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 9999 Heated Glass Element: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10000 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10001 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10002 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10003 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10004 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10005 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10006 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10007 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10008 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10009 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10010 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10011 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10012 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10013 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10014 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10015 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10016 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10017 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10018 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10019 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10020 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10021 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10022 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10023 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10024 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10025 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10026 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10027 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10028 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10029 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10030 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10031 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10032 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10033 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10034 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10035 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10036 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10037 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10038 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10039 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10040 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10041 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10042 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10043 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10044 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10045 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10046 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10047 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10048 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10049 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10050 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10051 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10052 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10053 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10054 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10055 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10056 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10057 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10058 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10059 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10060 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10061 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10062 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10063 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10064 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10065 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10066 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10067 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10068 Heated Glass Element: Connector Views Rear Window Defogger Grid C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10069 Rear Window Defogger Grid C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10070 Heated Glass Element: Electrical Diagrams Defogger Diagram Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 10071 Heated Glass Element: Description and Operation REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: HVAC control assembly - rear window defogger grid REAR WINDOW DEFOGGER OPERATION Battery positive voltage is supplied through the HTD MIR/RR-DEFOG fuse in the underhood fuse block to the HVAC control assembly. Ignition voltage is supplied through the HTR-A/C fuse in the IP fuse block to the HVAC control assembly. Ground for the HVAC control assembly is provided by G200. The circuits mentioned for the HVAC control assembly are primarily for the rear window defogger system. When you turn the ignition to the ON position, and depress the rear window defogger switch. The HVAC control assembly illuminates the rear window defogger indicator and allows battery positive voltage through the RR DEFOG fuse in the IP fuse block to the rear window defogger grid. Ground for the rear window defogger grid is provided by G403. When you start the engine and depress the rear window defogger switch, the defogger cycle lasts for 10 minutes. Further operation will result in 5 minute defogger cycles. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - HEATED GLASS ELEMENT Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Heated Glass Element in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10074 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - HEATED GLASS ELEMENT IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the Rear Window Defogger System. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Defogger Inoperative - Rear Window - Defogger Indicator Always On - Defogger Grid Lines Diagnosis Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10075 Steps 1-7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10076 Steps 1-3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10077 Steps 4-9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10078 Steps 10-16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10079 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 5. Once the open (2) is located, repair the grid line. Refer to Grid Line Repair. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Procedures Heated Glass Element: Procedures Body Side Stationary Window Replacement BODY SIDE STATIONARY WINDOW REPLACEMENT TOOLS REQUIRED - J 24402-A Glass Sealant (Cold Knife) Remover - J 39032 Stationary Glass Removal Tool - Urethane Adhesive Kit GM P/N 12346392 or Equivalent - Isopropyl Alcohol or Equivalent - Cartridge-type Caulking Gun - Commercial-type Utility Knife - Razor Blade Scraper - Suction Cups - Plastic Paddle REMOVAL PROCEDURE 1. When replacing or removing the left side stationary window.Refer to Trim Replacement - Third Pillar Left in Interior Trim or Trim Replacement Fourth Pillar Left in Interior Trim. CAUTION: Refer to Cracked Window Caution in Service Precautions. IMPORTANT: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 2. When replacing or removing the right side stationary window.Refer to Trim Replacement - Third Pillar Right in Interior Trim or Trim Replacement - Fourth Pillar Right in Interior Trim. 3. Cover to protect the following parts from broken glass: 3.1. Upper dash pad 3.2. Defroster outlets and A/C outlets 3.3. Seats and carpeting CAUTION: Refer to Defroster Outlet Caution in Service Precautions. 4. Using a sharp utility knife, make a preliminary cut around the perimeter of the stationary window. CAUTION: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Procedures > Page 10082 5. This will allow the urethane adhesive to be separated from the stationary window. - Leave a base of urethane on the pinchweld flange. - The only suitable lubrication is clear water. - Use J 24402-A , J 39032 or equivalent in order to remove the stationary window. IMPORTANT: Keep the cutting edge of the tool against the stationary window. Do this from inside the vehicle. 6. With the aid of an assistant, remove the stationary window from the opening. INSTALLATION PROCEDURE 1. Install the stationary window into the opening. 2. When replacing or removing the left side stationary window. Refer to Trim Replacement - Third Pillar Left in Interior Trim or Trim Replacement Fourth Pillar Left in Interior Trim. 3. When replacing or removing the right side stationary window. Refer to Trim Replacement - Third Pillar Right in Interior Trim or Trim Replacement - Fourth Pillar Right in Interior Trim. 4. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Grid Line Repair GRID LINE REPAIR TOOLS REQUIRED - J 25070 Heat Gun - Capable of 260°C (500°F) or equivalent - Test Lamp - Rear Window Defogger Repair Kit GM P/N 12346001, Canada P/N 10951643 or equivalent REMOVAL PROCEDURE 1. Disconnect the electrical connector. CAUTION: To avoid personal injury: Do not allow the repair material to come in contact with skin or eyes and avoid breathing vapors. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Procedures > Page 10083 - Do not use near sparks or open flame. 1. Inspect the rear window grid lines. 2. Ensure that the rear window is at room temperature. 3. Inspect the grid line area that you will repair. Verify that the area is dry and free from contaminates. 4. Dampen a cloth with isopropyl alcohol. Use the damp cloth in order to wipe the grid line area clean. INSTALLATION PROCEDURE 1. Use a grease pencil in order to mark the grid line break (2) on the outside of the rear window with a grease pencil. IMPORTANT: Ensure that the grid line repair material is not beyond the expiration date. - Repair decal or tape must be used in order to control the width of the repair area. - If the repair decal is used, verify that the die-cut metering slot is the same width as the grid line. - Thoroughly stir the grid line repair material until a uniform color appears. - Verify that there are no air bubbles in the grid line repair material in the repair area. 1. Using GM P/N 12346001 (Canadian P/N 10951643) or equivalent to repair the grid lines. Apply the grid line repair (2) decal or 2 strips of the tape above and below the repair area. 2. Use the brush (3) in order to spread the grid line repair material (1). Ensure that the repair material covers all of the areas of the cut out. 3. Without disturbing the grid line repair material, carefully remove the decal or tape (2). NOTE: The grid line repair material must be cured with heat. To avoid heat damage to the interior trim, protect the trim near the repair area where heat is to be applied. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Procedures > Page 10084 4. Use a heat gun in order to repair the grid line: - Hold the heat gun nozzle 25 mm (1 in) from the surface. - Heat the repair area for 2-3 minutes. IMPORTANT: Use J 25070 capable of 260°C (500°F) or equivalent. If you do not use a heat gun, allow at least 24 hours at an ambient temperature of 21-32°C (70-90°F) for complete curing of the repair materials. Do NOT physically disturb the repair area until after that time. The grid line will be electrically operative immediately after the repair. 5. Connect the electrical connector. 6. Test the grid line operation in order to verify the grid line repair. Rear Window Defogger Braided Lead Wire REAR WINDOW DEFOGGER BRAIDED LEAD WIRE 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. CAUTION: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: - The rear defogger bus bar lead wire - The defogger terminal repair area 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. CAUTION: Refer to Window Retention Caution in Service Precautions. IMPORTANT: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 7. Align the spots with the flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Procedures > Page 10085 - The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: - The rear defogger bus bar lead wire - The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: - The top of the rear defogger bus bar lead wire - The defogger terminal 14. Remove the excess flux with the solvent. IMPORTANT: Do not remove the holding force until the solder has solidified. 15. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Procedures > Page 10086 Heated Glass Element: Removal and Replacement Rear Window Defogger Braided Lead Wire Caution: Refer to Glass and Sheet Metal Handling Caution in Cautions and Notices. 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: * The rear defogger bus bar lead wire * The defogger terminal repair area Caution: Refer to Window Retention Caution in Cautions and Notices. Important: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 7. Align the spots with the flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: * The rear defogger bus bar lead wire * The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: * The top of the rear defogger bus bar lead wire * The defogger terminal Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Procedures > Page 10087 Important: Do not remove the holding force until the solder has solidified. 14. Remove the excess flux with the solvent. 15. Connect the electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection > Page 10092 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Page 10093 HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10096 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10097 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10098 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10099 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10100 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10101 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10102 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10103 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10104 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10105 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10106 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10107 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10108 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10109 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10110 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10111 Rear Defogger: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10112 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10113 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10114 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10115 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10116 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10117 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10118 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10119 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10120 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10121 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10122 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10123 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10124 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10125 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10126 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10127 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10128 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10129 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10130 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10131 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10132 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10133 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10134 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10135 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10136 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10137 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10138 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10139 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10140 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10141 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10142 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10143 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10144 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10145 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10146 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10147 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10148 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10149 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10150 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10151 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10152 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10153 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10154 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10155 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10156 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10157 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10158 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10159 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10160 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10161 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10162 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10163 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10164 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10165 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10166 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10167 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10168 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10169 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10170 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10171 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10172 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10173 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10174 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10175 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10176 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10177 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10178 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10179 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10186 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10187 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10188 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10189 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10190 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10191 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10192 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10193 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10194 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10195 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10196 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10197 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10198 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10199 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10200 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10201 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10202 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10203 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10204 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10205 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10206 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10207 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10208 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10209 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10210 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10211 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10212 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10213 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10214 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10215 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10216 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10217 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10218 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10219 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10220 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10221 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10222 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10223 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10224 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10225 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10226 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10227 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10228 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10229 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10230 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10231 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10232 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10233 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10234 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10235 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10236 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10237 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10238 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10239 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10240 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10241 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10242 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10243 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10244 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10245 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10246 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10247 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10248 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10249 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10250 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10251 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10252 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10253 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10254 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10255 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10256 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10257 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10258 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10259 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10260 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 Power Window Switch: Connector Views Window Master Switch - Driver C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 Window Master Switch - Driver C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 Window Switch - Front Passenger C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 Window Switch - Front Passenger C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 Window Switch - Front Passenger C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 10275 Power Window Switch: Service and Repair ACCESSORY SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Disconnect the electrical connectors. 3. Squeeze the lock tabs in order to remove the switches. INSTALLATION PROCEDURE 1. Push in on the switches in order to install the switches to the plate. 2. Connect the electrical connector. 3. Install the instrument panel cluster trim plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Motor Replacement - Power Window Removal Procedure 1. Remove the power window regulator. Refer to Window Regulator Replacement (See: Window Regulator/Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install a self-tapping, pan head sheet metal screw through the sector gear and the backing plate at the hole provided. This will lock the sector gear into position. 3. Drill out the rivets (2) attaching the power window motor to window regulator . 4. Remove the power window motor from the window regulator (3). Installation Procedure 1. Install the power window motor to the window regulator (3). Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install the rivets (2) attaching the power window motor to window regulator . 3. Remove the self-tapping, pan head sheet metal screw through the sector gear and the backing plate hole. 4. Install the power window regulator. Refer to Window Regulator Replacement (See: Window Regulator/Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Door Control Switches - Driver Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10286 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10287 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10288 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10289 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10290 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10291 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10292 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10298 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10299 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10300 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10301 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10302 Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10303 The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10304 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10305 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10306 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing for Proper Terminal Contact TOOLS REQUIRED J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10307 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10308 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10309 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10310 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10311 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(r) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(r) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(r) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(r) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(r) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10312 Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10313 also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10314 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10315 SIR/SRS Connector (Plastic Body And Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10316 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10317 SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10318 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10319 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10320 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10321 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10322 Equivalents - Decimal And Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10323 Equivalents - Decimal And Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10324 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10325 Various symbols in order to describe different service operations. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10326 Conversion - English/Metric Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10327 Conversion - English/Metric Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10328 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10329 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English,inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 - M8 X 1.25 - M10 X 1.5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10330 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10331 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10332 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10333 English Prevailing Torque Fastener Minimum Torque Development Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10334 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10335 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10336 the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non - Registered Trademarks Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10337 Registered And Non - Registered Trademarks Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10338 Registered And Non - Registered Trademarks Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10339 Registered And Non - Registered Trademarks Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10340 Registered And Non - Registered Trademarks Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10341 Registered And Non - Registered Trademarks Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10342 Registered And Non - Registered Trademarks Part 7 Listed are Registered Trademarks (R) or Non-Registered Trademarks (TM) which may appear. Abberivations and Meanings ABBERIVATIONS AND MEANINGS Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10343 Abbreviations And Meanings Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10344 Abbreviations And Meanings Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10345 Abbreviations And Meanings Part 3 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10346 Abbreviations And Meanings Part 4 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10347 Abbreviations And Meanings Part 5 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10348 Abbreviations And Meanings Part 6 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10349 Abbreviations And Meanings Part 7 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10350 Abbreviations And Meanings Part 8 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10351 Abbreviations And Meanings Part 9 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10352 Abbreviations And Meanings Part 10 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10353 Abbreviations And Meanings Part 11 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10354 Abbreviations And Meanings Part 12 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10355 Abbreviations And Meanings Part 13 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10356 Abbreviations And Meanings Part 14 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10357 Abbreviations And Meanings Part 15 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10358 Abbreviations And Meanings Part 16 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10359 Abbreviations And Meanings Part 17 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10360 Abbreviations And Meanings Part 18 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10361 Abbreviations And Meanings Part 19 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10362 Abbreviations And Meanings Part 20 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10363 Abbreviations And Meanings Part 21 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10364 Abbreviations And Meanings Part 22 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10365 Abbreviations And Meanings Part 23 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10366 Abbreviations And Meanings Part 24 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10367 Abbreviations And Meanings Part 25 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10368 Abbreviations And Meanings Part 26 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10369 Abbreviations And Meanings Part 27 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10370 Power Window Switch: Connector Views Window Master Switch - Driver C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10371 Window Master Switch - Driver C2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10372 Window Switch - Front Passenger C1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10373 Window Switch - Front Passenger C2 Part 1 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10374 Window Switch - Front Passenger C2 Part 2 Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 10375 Power Window Switch: Service and Repair ACCESSORY SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Disconnect the electrical connectors. 3. Squeeze the lock tabs in order to remove the switches. INSTALLATION PROCEDURE 1. Push in on the switches in order to install the switches to the plate. 2. Connect the electrical connector. 3. Install the instrument panel cluster trim plate. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10385 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10386 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10387 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10393 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10394 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10395 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Upper Removal Procedure 1. Pull the molding (1) from the molding flange. 2. Remove the molding (1). Installation Procedure 1. Install the molding (1). 2. Push the molding (1) onto the flange. Start at the pre-formed corners. Work toward the straight flanges. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair Window Replacement - Lift Gate Tools Required * J 24402-A Glass Sealant (Cold Knife) Remover * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: Refer to Cracked Window Caution in Cautions and Notices. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Disconnect the washer hose from the liftgate. 2. Remove the back window wiper arm from the liftgate. Refer to Wiper Arm Replacement - Rear in Wipers/Washer Systems. 3. Open liftgate window. 4. Disconnect the electrical connector from the rear window defogger on the liftgate window. Caution: Refer to Defroster Outlet Caution in Cautions and Notices. 5. Cover to protect the following parts from broken glass: 1. Upper dash pad 2. Defroster outlets and A/C outlets 3. Seats and carpeting Important: Keep the cutting edge of the tool against the window. 6. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A , J 39032 or equivalent in order to remove the window. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 10416 7. With the aid of an assistant, remove the liftgate window from the liftgate frame. Installation Procedure 1. Install a stationary window into the opening. Refer to Urethane Adhesive Installation of Stationary Windows (See: Service and Repair/Removal and Replacement/Urethane Adhesive Installation of Stationary Windows) . 2. Connect the electrical connector to the rear window defogger on the liftgate window. 3. Close liftgate window. 4. Install the back window wiper arm to the liftgate. Refer toWiper Arm Replacement - Rear in Wipers/Washer Systems. 5. Connect the washer hose to the liftgate. 6. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Quarter Window Glass Weatherstrip > Component Information > Service and Repair Quarter Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Swing Out Window Removal Procedure 1. Open the swing out window. 2. Pull the weatherstrip from the pinch weld flange. 3. Grasp the weatherstrip at the lower corner and pull up and away from the pinch-weld. Installation Procedure 1. Install the weatherstrip to the pinch-weld flange. 2. Put the weatherstrip on the pinch-weld flange and push downward until fully seated. 3. Close the swing out window. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Replacement Door Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Remove the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward. and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure 1. Install the regulator (3) to the door: 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Front Side Door Water Deflector Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 5. Install the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 6. Remove the tape from the door and the window. 7. Check the window operation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 10426 8. Install the trim panel. Refer to Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 10427 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Remove the bolts that retain the inner panel upper bar. 3. Remove the water deflector. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 10428 1. Install the regulator (3) to the door: 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. 5. Install the inner panel upper bar with the bolts. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the tape from the door and the window. 7. Check the window operation. 8. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair Window Track: Service and Repair Window Run Channel Replacement Removal Procedure 1. Roll the window up completely. 2. Remove the trim panel. Refer to Trim Panel Replacement Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 3. Use a sharp bladed tool, if needed, in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. 4. Remove the door to window run channel bolt. 5. Pull the run channel away from the upper channel (which is part of the door) in order to remove the window run channel from the door. Installation Procedure 1. Slide the clip of the channel into the upper channel in order to install the window run channel to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the door to window run channel bolt. Tighten the door to window run channel bolt to 9.5 N.m (84 lb in). 3. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. 4. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Cruise Control Module, And Wiper Motor Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10437 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10438 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10439 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10440 Wiper Control Module: Diagrams Rear Window Wiper/Washer Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10441 Windshield Wiper Motor and Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Wiper Motor Module Replacement (Front) Wiper Control Module: Service and Repair Wiper Motor Module Replacement (Front) WIPER MOTOR MODULE REPLACEMENT (FRONT) REMOVAL PROCEDURE 1. Remove the wiper motor electrical connector. 2. Remove the cover screws. 3. Remove the cover. 4. Remove the circuit board and terminal module by lifting up on the terminal. INSTALLATION PROCEDURE 1. Install the circuit board and terminal module. 2. Install the cover and 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.6 N.m (23 lb in). 3. Install the wiper motor electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Wiper Motor Module Replacement (Front) > Page 10444 Wiper Control Module: Service and Repair Wiper Motor Module Replacement (Rear) WIPER MOTOR MODULE REPLACEMENT (REAR) REMOVAL PROCEDURE 1. Remove the liftgate garnish molding. 2. Disconnect the two electrical connectors from the controller module assembly. 3. Drill the heads from the rivets with an appropriate drill bit. 4. Remove two rivets and the controller assembly from the liftgate. INSTALLATION PROCEDURE 1. Install the controller module assembly onto the liftgate. 2. Install two new rivets with a hand-held rivet gun. 3. Connect the two electrical connectors to the controller assembly. 4. Install the liftgate garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10449 Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10450 Rear Window Wiper/Washer Switch Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10454 Rear Window Wiper/Washer Switch Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10455 Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10456 Rear Window Wiper Washer Switch Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid > Component Information > Diagrams Rear Window Washer Fluid Pump Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair HOSE REPLACEMENT REMOVAL PROCEDURE 1. Remove coolant recovery reservoir. 2. Remove the washer solvent container. 3. Remove the washer hose from the rear washer pump to the rear washer check valve. 4. Remove the rear washer check valve. 5. Remove the washer hose from the front washer pump to the front washer check valve. 6. Remove the front washer check valve. 7. Remove the front washer hose and strap. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 10463 8. Remove the washer hose connector from the plenum clip. 9. Remove the RH washer nozzle hose and hose clip. 10. Remove the LH washer nozzle hose from the 2 plenum clips. 11. Remove the LH washer nozzle hose and hose clip. INSTALLATION PROCEDURE 1. Install the LH washer nozzle hose with the hose clip. 2. Install the LH washer nozzle hose in the 2 plenum clips. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 10464 3. Install the RH washer nozzle hose with the hose clip. 4. Install the washer hose connector in the plenum clip. 5. Install the front washer hose and strap. 6. Install the front washer check valve. 7. Install the washer hose from the front washer pump to the front washer check valve. 8. Install the rear washer check valve. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 10465 9. Install the washer hose from the rear washer pump to the rear washer check valve. 10. Install the washer solvent container. 11. Install the coolant recovery reservoir. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Fluid Pump Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 10469 Windshield Washer Pump: Service and Repair WASHER PUMP REPLACEMENT REMOVAL PROCEDURE 1. Remove coolant recovery reservoir. 2. Remove the washer solvent container. 3. Disconnect the washer hose(s). 4. Remove the washer pump(s) from the washer solvent container. INSTALLATION PROCEDURE 1. Install the washer pump(s) in the washer solvent container. 2. Connect the washer hose(s). 3. Install the washer solvent container. 4. Install the coolant recovery reservoir. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10473 Steering Column Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10474 Rear Window Wiper/Washer Switch Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Replacement Wiper Arm: Service and Repair Wiper Arm Replacement WIPER ARM REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer hose from the wiper arm. 2. Lift the wiper arm assembly from the windshield, then pull the retaining latch. IMPORTANT: Before removing one or both of the arm and blade assemblies, use a suitable marker on the windshield to indicate the proper part position and to aid in reinstallation. 3. Remove the arm assembly from the transmission drive shaft. INSTALLATION PROCEDURE 1. Position the wiper arm assembly on the drive shaft and press in the retaining latch so that the wiper blade aligns with the mark made before the removal. 2. Install the washer hose. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Replacement > Page 10479 Wiper Arm: Service and Repair Wiper Arm Replacement - Rear WIPER ARM REPLACEMENT - REAR REMOVAL PROCEDURE IMPORTANT: Mark the position of the wiper blade on the liftgate with a suitable marker or a piece of masking tape. 1. Pull the washer hose through the liftgate grommet. 2. Disconnect the washer hose from the washer harness connector. 3. Lift the wiper arm off the liftgate. 4. Push out the wiper arm retaining clip with a small screwdriver. 5. Remove the wiper arm from the wiper motor drive shaft. INSTALLATION PROCEDURE 1. Position the wiper arm onto the wiper motor drive shaft so that the tip of the blade aligns with the mark made at removal. 2. Install the wiper arm onto the drive shaft. 3. Press in the retaining clip. 4. Connect the washer hose onto the washer harness connector. 5. Insert the hose into the liftgate grommet. 6. Operate the rear wiper and inspect for proper operation. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 10484 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement WIPER ARM BLADE REPLACEMENT REMOVAL PROCEDURE 1. Insert a narrow-bladed screwdriver into the slot over the wiper blade retainer spring. 2. Pivot the screwdriver so that the blade tip presses downward on the retainer spring and releases the wiper blade from the pin of the wiper arm. 3. Remove the wiper blade from the wiper arm. INSTALLATION PROCEDURE 1. Install the wiper blade on the wiper arm pin. 2. Snap the wiper blade into place. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 10487 Wiper Blade: Service and Repair Wiper Blade Element Replacement WIPER BLADE ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the wiper blade from the wiper arm. IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 2. Squeeze the wiper blade element tabs together. 3. Pull the wiper blade element out through the wiper blade claws. INSTALLATION PROCEDURE 1. Slide the wiper blade element through the bottom claw of the wiper blade. 2. Guide the wiper blade element through the wiper blade claws until both of the locking tabs engage the bottom claw set. 3. Install the wiper blade on the wiper arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 10488 Wiper Blade: Service and Repair Blade Element Cleaning BLADE ELEMENT CLEANING Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 10489 Wiper Blade: Service and Repair Wiper Arm Blade Replacement - Rear WIPER ARM BLADE REPLACEMENT - REAR REMOVAL PROCEDURE 1. Insert a narrow-bladed screwdriver into the slot over the wiper blade retainer spring. 2. Pivot the screwdriver so that the blade tip presses downward on the retainer spring and releases the wiper blade from the pin of the wiper arm. 3. Remove the wiper blade from the wiper arm. INSTALLATION PROCEDURE 1. Install the wiper blade on the wiper arm pin. 2. Snap the wiper blade into place. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 10490 Wiper Blade: Service and Repair Blade Element Replacement - Rear BLADE ELEMENT REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the wiper blade from the wiper arm. IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 2. Squeeze the wiper blade element tabs together. 3. Pull the wiper blade element out through the wiper blade claws. INSTALLATION PROCEDURE 1. Slide the wiper blade element through the bottom claw of the wiper blade. 2. Guide the wiper blade element through the wiper blade claws until both of the locking tabs engage the bottom claw set. 3. Install the wiper blade on the wiper arm. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Cruise Control Module, And Wiper Motor Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10494 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10495 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10496 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10497 Wiper Control Module: Diagrams Rear Window Wiper/Washer Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10498 Windshield Wiper Motor and Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Wiper Motor Module Replacement (Front) Wiper Control Module: Service and Repair Wiper Motor Module Replacement (Front) WIPER MOTOR MODULE REPLACEMENT (FRONT) REMOVAL PROCEDURE 1. Remove the wiper motor electrical connector. 2. Remove the cover screws. 3. Remove the cover. 4. Remove the circuit board and terminal module by lifting up on the terminal. INSTALLATION PROCEDURE 1. Install the circuit board and terminal module. 2. Install the cover and 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.6 N.m (23 lb in). 3. Install the wiper motor electrical connector. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Wiper Motor Module Replacement (Front) > Page 10501 Wiper Control Module: Service and Repair Wiper Motor Module Replacement (Rear) WIPER MOTOR MODULE REPLACEMENT (REAR) REMOVAL PROCEDURE 1. Remove the liftgate garnish molding. 2. Disconnect the two electrical connectors from the controller module assembly. 3. Drill the heads from the rivets with an appropriate drill bit. 4. Remove two rivets and the controller assembly from the liftgate. INSTALLATION PROCEDURE 1. Install the controller module assembly onto the liftgate. 2. Install two new rivets with a hand-held rivet gun. 3. Connect the two electrical connectors to the controller assembly. 4. Install the liftgate garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Disconnect the transmission drive link from the wiper motor crank arm with the J 39232 . 4. Remove the transmission to cowl nuts. 5. Remove the wiper transmission from the vehicle through the access openings in the top of the cowl. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 10505 1. Install the wiper transmission on the vehicle. 2. Install the transmission to cowl nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the transmission nuts to 14 N.m (10 lb ft). 3. Connect the transmission drive link to the wiper motor crank arm using the J 39529. IMPORTANT: Assemble the wiper transmission to the crank arm past the second detent so that the seal is compressed to a maximum height of 25.5 mm (1.0 in). Lubricate the inside of the socket with a lithium-based grease (GM P/N 1050109, 1052196, Canadian P/N 5264008 or equivalent). 4. Install the air inlet grille panel. 5. Install the wiper arms. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10509 Cruise Control Module, And Wiper Motor Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10510 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10511 Engine/Center Of Front Dash Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10512 Cruise Control Module, And Wiper Motor Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10513 Liftgate Harness Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Wiper Motor: Connector Views Rear Window Wiper Motor Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views > Page 10516 Windshield Wiper Motor and Module Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement Wiper Motor: Service and Repair Wiper Motor Replacement WIPER MOTOR REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Disconnect the transmission drive link from the wiper motor crank arm using the J 39232 . 4. Remove the wiper motor electrical connector. 5. Remove the three bolts. 6. Remove the wiper motor from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 10519 1. Install the wiper motor on the vehicle. 2. Install the 3 bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the 3 bolts to 7.0 N.m (62 lb in). 3. Connect the wiper motor electrical connector. 4. Connect the transmission drive link to the crank arm using the J 39529. IMPORTANT: Assemble the wiper transmission to the crank arm past the second detent so that the seal is compressed to a maximum height of 25.5 mm (1.0 in). Lubricate the inside of the socket with a lithium-based grease (GM P/N 1050109, 1052196 or equivalent). 5. Install the air inlet grille panel. 6. Install the wiper arms. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 10520 Wiper Motor: Service and Repair Wiper Motor Replacement - Lift Gate WIPER MOTOR REPLACEMENT - LIFT GATE REMOVAL PROCEDURE 1. Remove the liftgate garnish molding. 2. Disconnect the wiper motor electrical connector. 3. Remove the wiper arm from the wiper motor. 4. Remove the nut, the spacer, and the seal. 5. Remove the 2 bolts and the wiper motor from the liftgate. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor to the liftgate with the 2 bolts. Tighten Tighten the bolts to 7.0 N.m (62 lb in). 2. Install the seal, the spacer, and the nut. Tighten Tighten the nut to 6.0 N.m (53 lb in). 3. Install the wiper arm and blade. 4. Connect the wiper motor electrical connector. 5. Install the liftgate garnish molding. Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations HVAC Panel Wiring Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10524 Rear Window Wiper/Washer Switch Location View Chevrolet Astro Van Awd Workshop Manual (V6-4.3L VIN X (2003)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10525 Steering Column